Auto Film Splicing Assembly with Roll Positioner
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Solution Overview
Problem
Current sheet material splicing systems are cumbersome, require many pieces-and-parts, and pose ergonomic challenges due to the need for precise roll positioning, which complicates semi-automated operations and maintenance, especially when handling heavy rolls.
Innovation Solution
A compact splicing assembly with a drive system, sealing elements, and a roll positioner using a linear actuator and pusher plate, facilitated by a controller, to automate the splicing and positioning of rolled sheet material on shafts, ensuring accurate and efficient roll exchange without manual labor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual roll positioning is used, then operator flexibility is maintained, but positioning precision deteriorates due to the difficulty of stopping heavy rolls within 1/8 inch accuracy
Solution Approach 1:
The patent replaces manual mechanical positioning with an automated positioning system that uses sensors and controlled drive mechanisms to achieve precise roll placement. The system automatically detects shaft positions and controls roll movement, eliminating the need for operators to manually position heavy rolls while achieving the required 1/8 inch precision.
2Reliability
If multiple pieces-and-parts are used in splicing systems, then splicing functionality is comprehensive, but system complexity increases making maintenance and operation difficult
Solution Approach 1:
The patent combines multiple splicing functions into an integrated automated splicing system. The system merges roll positioning, splicing execution, and accumulator coordination into a single controlled unit, reducing the number of separate components while maintaining comprehensive splicing functionality and improving ease of operation.
Solution Approach 2:
The automated splicing system is designed to handle multiple film widths and roll sizes through a universal positioning and splicing mechanism. The system can accommodate different roll configurations without requiring separate dedicated components for each scenario, thereby reducing overall system complexity while maintaining versatility.
3Productivity
If roll exchange operations are performed manually, then system simplicity is maintained, but operational downtime increases due to the time required for manual roll replacement
Solution Approach 1:
The system performs preliminary positioning of replacement rolls before they are needed for splicing. Rolls are pre-positioned on shafts using the automated positioning system, ready for immediate splicing operation. This preliminary action eliminates delays associated with manual roll handling and positioning during critical splicing operations.
Solution Approach 2:
The automated splicing system performs self-service by automatically detecting when rolls need changing, positioning replacement rolls, executing the splicing operation, and coordinating with the accumulator to maintain continuous operation. This self-service capability significantly reduces operational downtime without requiring manual intervention.
4Ease of operation
If heavy rolls are handled manually, then equipment cost is reduced, but ergonomic conditions deteriorate creating unfavorable working conditions
Solution Approach 1:
The patent replaces manual mechanical handling of heavy rolls with an automated positioning system that uses controlled drive mechanisms and sensors. This substitution eliminates the need for operators to physically handle heavy rolls, improving ergonomic conditions while maintaining cost-effectiveness through a relatively simple automated system.
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 seamless, semi-automated splicing operations with reduced operational downtime, improved ergonomics, and precise roll positioning, reducing the complexity of managing multiple film sizes and maintaining continuous production.
Implementation Method 1
a linear actuator and pusher plate, to automate the splicing and positioning of rolled sheet material on shafts
Implementation Method 2
A splicing apparatus includes first and second sealing elements and first and second sheet material carriages
Data Source
AI summary
A splicing assembly for rolled sheet material, including first and second shafts for support of sheet material and a drive assembly for selectively dispensing sheet material. The assembly further includes a splicing apparatus for uniting a replacement with a winding down roll, and an egress guide assembly for receipt of dispensed sheet material exiting the splicing apparatus and passage of same intermediate the shafts. The splicing apparatus includes first and second sealing elements, and first and second carriages adapted and disposed for translation towards their respective sealing elements, a free end portion of sheet material of the replacement roll supported upon the first/second shaft for selective retention by the second/first sheet material carriage, and for translation to, and thereafter with, a portion of sheet material of the winding down roll supported upon the second/first shaft for urged combined engagement with a corresponding sealing element.