Compact Roll Stand for Flexible Material Coils
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Solution Overview
Problem
Existing systems for handling and replacing rolls of flexible material in thermoforming and plastic injection machines require significant space, cause frequent interruptions in production, and necessitate extensive logistical efforts, leading to inefficiencies and operational challenges.
Innovation Solution
A compact roll stand system designed to accommodate two rolls of material simultaneously, featuring a main tubular structure with high resistance pins for stability, safety bars for protection, and a modular design that allows for vertical arrangement, reducing space requirements and enabling continuous material feeding without machine shutdowns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a horizontal arrangement system is used to support rolls of material, then the rolls can be easily accessed and replaced, but the device requires excessive space (more than 9m2) and causes frequent production interruptions
Solution Approach 1:
The patent transitions from a horizontal arrangement to a vertical arrangement of rolls. The support device includes a vertical column with multiple levels (first level and second level) that hold rolls in a vertical sequence. This dimensional change allows the rolls to be accessed and replaced through a ladder on the vertical column, eliminating the need for extensive horizontal space while maintaining operational accessibility.
2Device complexity
If manual roll replacement is performed, then the device structure can be simple, but production is interrupted for approximately 15 minutes every 16 hours
Solution Approach 1:
The patent implements a system where rolls are pre-positioned on the vertical column at different levels. The support device includes a mechanism that allows the roll to be replaced without requiring the entire device to be disassembled or complex operational procedures to be performed. The vertical arrangement with ladder access enables operators to replace rolls efficiently while maintaining production continuity.
3Weight of moving object
If a forklift is used to load rolls, then heavy rolls can be easily handled, but safety risks increase due to potential contact with the tubular structure
Solution Approach 1:
The patent incorporates a protective cage or shielding structure around the tubular column and roll support areas. This protective element is positioned beforehand to prevent forklift contact with the tubular structure during loading operations. The cage acts as a buffer that absorbs or deflects potential impacts from forklift operations, thereby reducing safety risks while maintaining the ability to handle heavy rolls.
4Ease of operation
If rolls are arranged horizontally, then the feeding process is simple, but the device cannot maximize work area utilization and requires constant suspension for adjustments
Solution Approach 1:
The patent reconfigures the roll arrangement from horizontal to vertical, utilizing the vertical dimension to maximize work area utilization. The vertical column with multiple levels allows multiple rolls to be stored and fed in sequence without requiring extensive horizontal space. The feeding mechanism operates through this vertical arrangement, maintaining simplicity while significantly improving space efficiency and eliminating the need for constant suspension for adjustments.
Data Source
AI summary
A device compact roll stand for coils that allows two rolls of material (coils) to be simultaneously incorporated, for feeding systems that process and package different products, especially thermoformed products (polypropylene, polystyrene, high barrier, and PET materials). It has a safety system, cutting bench, and access mechanism for handling by the personnel responsible for the same, it can be transported, and it allows spaces in the industrial sector to be optimized and the feeding process of the flexible material to continue, without having to stall the operation or pause the packaging for long periods of time due to the swapping and replacement of the rolls of material.