Cellulose Web Splicing for Continuous Mixed Fluff Production
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Solution Overview
Problem
Defibrator mills are unable to produce cellulose fluff formed by a mixture of two different cellulose fibers without stopping the feed, as synchronizing the feed speeds of two cellulose webs of different types during reel changes is challenging.
Innovation Solution
A machine and method that allows simultaneous feeding of two cellulose webs of different types into a defibrator mill by using splicing apparatuses to join tail and head portions of the webs with adhesive tapes, ensuring continuous operation during reel changes, and adjusting the composition of the cellulose fluff mixture by varying feed device speeds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If two cellulose webs of different types are fed simultaneously into the defibrator mill, then the production of mixed cellulose fluff is enabled, but the reel change process becomes complex and requires precise feed speed synchronization
Solution Approach 1:
The system divides the feed management into separate controllable units with individual feed devices for each web. Each feed device can be independently controlled and synchronized, breaking down the complex synchronization task into manageable segments that can be coordinated through the control unit.
Solution Approach 2:
The feed devices are designed with variable speed capabilities, allowing dynamic adjustment of feed speeds during operation. This enables the system to adapt feed rates in real-time to maintain synchronization during reel changes and to optimize the mixture composition of cellulose fluff.
2Productivity
If reel changes are performed during simultaneous feeding of two cellulose webs, then continuous production is maintained, but web jamming risk increases
Solution Approach 1:
The control unit receives feedback signals from sensors that monitor web position, feed speed, and reel status. This feedback enables real-time detection of potential jamming conditions and automatic adjustment of feed speeds to prevent web entanglement during reel changes.
Solution Approach 2:
The system prepares for reel changes in advance by monitoring reel status and pre-adjusting feed speeds before the change occurs. The control unit coordinates the timing of reel replacement with the feed devices to ensure smooth transitions without web disruption.
3Stability of the object's composition
If feed speeds of two cellulose webs are synchronized during reel changes, then constant fluff production flow rate is maintained, but control precision requirements increase
Solution Approach 1:
Sensors monitor the actual feed speeds and fluff production rate, providing feedback to the control unit. The control unit continuously adjusts the feed device speeds to maintain the target flow rate, compensating for variations and ensuring stable production composition.
Solution Approach 2:
The system dynamically changes feed speed parameters during operation based on reel status and production requirements. The control unit modifies speed settings to maintain optimal fluff production flow rate while adapting to different reel configurations and cellulose web properties.
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
Enables the production of cellulose fluff with a mixture of long-fiber and short-fiber cellulose without stopping the mill, maintaining a constant fluff flow rate and preventing web jamming, thus enhancing production efficiency and sustainability.
Implementation Method 1
applying a first adhesive splicing tape between a tail end of the first web and a head end of the second web
Data Source
AI summary
A method for joining together two webs includes: overlapping a head portion of the second web on a tail portion of the first web, jointly cutting the head portion of the second web and the tail portion of the first web along a cutting line, so as to form on the first web and on the second web respective front edges offset from each other, and applying a first adhesive splicing tape between a head end of the second web and a tail end of the first web and at the same time aligning frontally with each other the front edges of the first and the second webs.