Center Surface Rewinder Independent Modules
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Solution Overview
Problem
Conventional turret winders shut down due to core load faults or web breaks, leading to production losses and the need for immediate repair, and lack the ability to produce rolled products with varying characteristics efficiently.
Innovation Solution
A winder system with independent winding modules and a core loading apparatus that allows for continuous operation by enabling the loading and unloading of cores, and the use of both center and surface winding techniques to produce rolled products with varying degrees of softness and hardness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional turret winders are used with center winding technique, then soft-wound higher bulk rolled products can be efficiently produced, but the machine must shut down when core load faults or web break faults occur
Solution Approach 1:
The winder is divided into multiple independent winding modules (first winding module, second winding module, etc.), each capable of independent operation. When a fault occurs in one module, other modules can continue operating, eliminating the need for complete machine shutdown and maintaining continuous production.
Solution Approach 2:
The system can switch between different winding techniques (center winding, surface winding, or combination) by adjusting operational parameters. This allows flexible adaptation to produce rolled products with varying characteristics while maintaining continuous operation through redundant modules.
2Ease of repair
If the machine shuts down for fault correction, then proper repair can be performed, but production loss occurs and immediate repair services are required
Solution Approach 1:
The redundant winding modules ensure that useful production action continues uninterrupted when faults occur in other modules. The system maintains continuous operation by redistributing workload to functioning modules, eliminating production downtime associated with fault correction.
3Productivity
If center winding technique is used, then soft-wound higher bulk rolled products are produced efficiently, but the ability to produce hard-wound lower bulk rolled products is limited
Solution Approach 1:
Each winding module is designed with multi-functionality, capable of performing both center winding and surface winding techniques. This universal design allows the same hardware to produce varied product characteristics (soft-wound high bulk or hard-wound low bulk) by adjusting operational mode, enhancing system versatility.
Solution Approach 2:
The winding modules can dynamically switch between different winding techniques based on production requirements. The system adapts its operational characteristics in real-time, transitioning between center winding for soft-wound products and surface winding for hard-wound products, providing flexible control over product properties.
4Productivity
If surface winding technique is used, then hard-wound lower bulk rolled products are produced efficiently, but the ability to produce soft-wound higher bulk rolled products is limited
Solution Approach 1:
The winding modules are designed with universal capability to perform both surface winding and center winding techniques. This allows the same equipment to efficiently produce hard-wound low bulk products via surface winding while retaining the ability to produce soft-wound high bulk products via center winding, maximizing versatility.
Solution Approach 2:
The system dynamically adjusts its winding approach based on desired product characteristics. When hard-wound low bulk products are needed, surface winding is employed; when soft-wound high bulk products are required, center winding is used. This dynamic adaptation ensures efficient production across different product types.
Data Source
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AI summary
A core loading apparatus is provided for use in a winder for winding a web to produce a rolled product. The core loading apparatus includes a mandrel (26) and a core loading assembly (200) configured to slide across the mandrel (26) and including a gripping device (202) with at least two gripping members moveable towards and away from each other. The core loading apparatus further comprises an actuator (208) configured to move the core loading assembly (200) back and forth across the mandrel (26). The gripping members (218) of the gripping device (202) engage a core (24) at the first end of the mandrel (26) while the actuator moves the core loading assembly (200) towards the second end of the mandrel (26) thereby pulling a core (24) onto the mandrel (26).