Two-Drum Belt Winder for Tissue Web Stability
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Solution Overview
Problem
Existing methods for winding paper webs, especially bulky tissue webs, face challenges in maintaining web stability and control at higher production speeds, leading to uneven rolls and increased complexity with vacuum boxes, which are prone to issues like plugging and safety hazards.
Innovation Solution
A two-drum belt winder system where the first and second support drums are fixedly mounted, with a looped belt forming nips to control web tension by varying the surface speed differential between the drums and maintaining minimal nip pressure, ensuring consistent web support and strain throughout the winding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If vacuum boxes are used to hold the tissue web to the transfer belt, then web stability is improved, but device complexity increases and safety hazards arise
Solution Approach 1:
The patent removes the vacuum box system entirely from the winding apparatus. Instead of using vacuum boxes to hold the web, the invention uses a simple transfer belt that passes over support drums, eliminating the complex vacuum system while maintaining web control through the belt's physical support and friction.
Solution Approach 2:
The invention replaces the complex, maintenance-intensive vacuum box system with a simple, inexpensive transfer belt that can be easily replaced. The belt is a basic mechanical component without moving parts or complex mechanisms, making it much simpler and safer to operate.
2Productivity
If machine speed of the belted reel is increased, then productivity is improved, but web handling becomes problematic
Solution Approach 1:
The patent employs dynamically adjustable support drums that can vary their surface speed independently. The first support drum and second support drum can rotate at different speeds, allowing the system to adapt to varying production requirements while maintaining proper web tension and control at high speeds. This dynamic speed adjustment prevents web wandering and maintains stability.
3Stability of the object's composition
If vacuum boxes are used to control tissue web, then web control is improved, but fire or explosion hazard increases
Solution Approach 1:
The invention eliminates the fire and explosion hazards associated with vacuum boxes by completely removing the vacuum system. The transfer belt operates using simple mechanical friction and support, with no air permeability requirements or dust accumulation issues, thereby converting a potentially hazardous system into a safe mechanical system.
4Device complexity
If pressure applied by the reel is concentrated at one nip, then web control is simplified, but manufacturing precision decreases
Solution Approach 1:
The patent divides the single nip into two separate nips by introducing a second support drum. The first nip between the transfer belt and reel applies initial web control, while the second nip between the second support drum and reel provides additional control points. This segmentation of the pressure application into two distinct locations improves roll uniformity and manufacturing precision.
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
This approach results in more uniform, dimensionally stable parent rolls with improved web control and reduced defects, allowing for higher production speeds without the complexities and hazards associated with vacuum systems.
Implementation Method 1
a looped belt forming nips to control web tension
Implementation Method 2
forming a first nip with the reel
Implementation Method 3
the second support drum forms a second nip with the reel
Implementation Method 4
forming a second nip with the reel
Implementation Method 5
By operating the second support drum at a higher surface speed relative to the reel and the belt, strain may be imparted to the web
Data Source
Figure 1
Figure 2~3
AI summary
The present invention provides an improved belted reel which is particularly well suited for the winding of soft, bulky tissue webs and overcomes the limitations of the prior art. The belted reel is capable of providing coordinated web tension and nip control by providing the winding parent roll with two nip points - the first nip formed between the winding roll and the second between the winding roll and a second support drum. Preferably the drum encircled by the endless belt lies above the second support drum and the first and second nip points lie in the same vertical plane.