Automated Overwrap System for Paper Bobbins
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing process for applying an overwrap material to bobbins of sheet-like products, such as paper, is labor-intensive and often results in non-uniform products, necessitating a more efficient and automated method that meets customer specifications.
Innovation Solution
An automated system and method involving a mandrel, breakfoot, vacuum roller, adhesive applicators, and cutting devices to securely attach and wrap the overwrap material around the bobbin, ensuring uniformity and adherence to specifications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If an automated system is implemented for applying overwrap material to bobbins, then productivity and uniformity are improved, but device complexity increases
Solution Approach 1:
The automated overwrap application system is divided into distinct functional modules: a breakfoot mechanism for opening sealed bobbins, adhesive applicators for applying adhesive material, overwrap material feeders, and sealing mechanisms. Each module operates independently but coordinates with others, allowing the system to achieve high productivity while managing complexity through modular design.
Solution Approach 2:
The system incorporates self-contained mechanisms such as automatic adhesive application where the adhesive applicator automatically positions and applies adhesive without manual intervention, and self-aligning overwrap feeding mechanisms that automatically position the overwrap material correctly on the bobbin, reducing the need for complex control systems.
2Manufacturing precision
If manual overwrap application is performed by operators, then device complexity is low, but manufacturing precision and uniformity deteriorate
Solution Approach 1:
The system replaces manual mechanical operations with automated mechanisms. The breakfoot mechanism automatically opens sealed bobbins without manual intervention, adhesive applicators precisely apply adhesive material in controlled patterns, and automated feeders ensure uniform overwrap material application, eliminating the variability inherent in manual operations.
Solution Approach 2:
The system maintains consistent application parameters such as adhesive application rate, overwrap tension, and sealing temperature through automated control, ensuring uniformity across all bobbins processed. This eliminates the parameter variations that occur when different operators perform manual application.
3Productivity
If breakfoot is used to open sealed bobbins, then productivity is improved, but the outer layer of paper may be damaged
Solution Approach 1:
The breakfoot mechanism applies force only to the sealed outer layer of the bobbin without excessive force that would damage the inner paper layers. The system uses just enough force to break the seal while preserving the integrity of the paper product inside, achieving quick opening while preventing damage.
4Productivity
If overwrap material is applied manually after parent bobbins are produced, then adaptability to different bobbin sizes is high, but productivity deteriorates
Solution Approach 1:
The automated system incorporates adjustable components that can be dynamically reconfigured for different bobbin sizes and specifications. The overwrap feeder mechanism, adhesive applicator positioning, and breakfoot force can be adjusted based on the specific bobbin being processed, allowing the system to maintain high productivity while adapting to various product requirements.
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 system enables fast, labor-free, and uniform application of the overwrap material, reducing manual errors and ensuring consistent product quality.
Implementation Method 1
a breakfoot is placed against an outer circumference of the bobbin. The breakfoot, for instance, may comprise a hydraulic or pneumatic actuator. Once the breakfoot is placed against the outer circumference, the outer layer of paper is then pulled causing the outer layer to break
Implementation Method 2
The leading edge of the bobbin can then be attached to a leading edge of an overwrap material by applying an adhesive material. The leading edge of the bobbin may be drawn against a vacuum roll positioned adjacent to the bobbin. The leading edge of the overwrap material, on the other hand, may be held on a vacuum plate
Implementation Method 3
The leading edge of the bobbin can then be attached to a leading edge of an overwrap material by applying an adhesive material in between the leading edge of the paper and the leading edge of the overwrap material
Data Source
AI summary
A system and method for placing an overwrap material on a bobbin of material is disclosed. The bobbin of material may be, for instance, a bobbin of paper, such as cigarette paper. The system automatically attaches the overwrap material to a leading edge of the bobbin, wraps the bobbin in the overwrap material, cuts the overwrap material, and secures the overwrap material to the bobbin. The overwrap material is used to protect the bobbin during shipping and storage. The overwrap material can also be used to assist in feeding of the bobbin of material into a process.