Adhesive Spreading Roller Cleaning System
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Solution Overview
Problem
Current adhesive-spreading assemblies require manual cleaning, which is inefficient, hazardous for operators, and poses safety risks due to the need for manual access inside machines and handling of chemical solvents, leading to prolonged downtime and potential accidents.
Innovation Solution
An automated roller-cleaning device with a transfer system that moves a distributor head parallel to the rollers, using a cleaning fluid system integrated with the machine, allowing for complete and even distribution of cleaning fluids without manual intervention, utilizing a pneumatically-controlled pump and controlled by a PLC program to ensure safety and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual cleaning procedure is used, then operator can access and clean rollers, but operator safety is compromised and cleaning time is excessive
Solution Approach 1:
The system enables self-service cleaning where the machine cleans itself automatically without operator intervention. The cleaning fluid is automatically pumped through distributors that move along the rollers, and the used fluid is automatically collected and drained, eliminating the need for manual cleaning operations.
Solution Approach 2:
The manual mechanical cleaning operation is replaced by an automated fluid-based cleaning system. Instead of operators physically rubbing rollers with cloths, the system uses pumped cleaning fluid delivered through movable distributors to automatically clean the rollers during machine operation or idle periods.
2Reliability
If manual cleaning is performed, then rollers can be cleaned, but operator exposure to harmful chemicals increases
Solution Approach 1:
The cleaning system operates autonomously without operator involvement in the cleaning process. The pump, distributors, and drainage system work automatically to clean the rollers, completely eliminating operator exposure to harmful cleaning chemicals while maintaining effective cleaning performance.
Solution Approach 2:
The cleaning fluid acts as an intermediary that performs the cleaning function without requiring operator contact with either the rollers or the chemicals. The fluid delivers the cleaning action remotely, while the drainage system intermediates the removal of used fluid, keeping operators isolated from harmful substances throughout the entire cleaning process.
3Productivity
If manual cleaning procedure is used, then rollers can be accessed, but productivity is reduced due to prolonged downtime
Solution Approach 1:
The cleaning system can operate continuously during machine idle periods or between production runs without requiring complete shutdown. The automated fluid circulation and roller cleaning can proceed uninterrupted, maximizing machine availability and minimizing productivity loss associated with cleaning operations.
Solution Approach 2:
The machine performs its own cleaning automatically, eliminating the need for external manual intervention that causes production delays. This self-cleaning capability ensures minimal downtime and maintains high machine availability for productive operation.
4Productivity
If automated cleaning system is added, then cleaning efficiency improves, but device complexity increases
Solution Approach 1:
The pump system serves multiple functions: it delivers cleaning fluid to distributors, circulates fluid through the system, and enables controlled fluid application to rollers. The distributors themselves are multi-functional, both delivering fluid and moving along the rollers to ensure complete coverage. This multi-functionality reduces the need for separate dedicated components.
Solution Approach 2:
The cleaning system merges several functions into integrated components: the distributors combine fluid delivery nozzles with movement mechanisms along the rollers. The drainage system merges collection and removal functions. This consolidation reduces overall system complexity while maintaining high cleaning efficiency.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enables quick, complete, and safe automatic cleaning of adhesive-spreading rollers, reducing machine downtime, eliminating operator safety risks, and maintaining the rollers' surface integrity without requiring modifications to existing machines.
Implementation Method 1
pumping means for delivering said fluid to distributor means designed to apply a part of said fluid to the surface of the rollers
Implementation Method 2
distributor means designed to apply a part of said fluid to the surface of the rollers
Data Source
AI summary
An adhesive-spreading assembly includes a plurality of rollers (R), that rotate in contact with one another to transfer a thin layer of adhesive from a tank (T) onto a film in motion, complete with a device for cleaning the rollers (R), removably connectable to the adhesive-spreading assembly and including at least one tank (5, 6) containing at least one cleaning fluid and pumping elements (8) for transferring the fluid to distributor elements (12) for delivering a part of the fluid onto the surface of the rollers (R). The adhesive-spreading assembly includes a transfer system (15) designed to transfer the distributor elements (12) in a direction substantially parallel to the axis of the rollers to distribute the fluid over their whole surface, the transfer system being configured so that it can be removably coupled with the distributor elements.