Converting Machine Automatic Rewinding Coil Change
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Solution Overview
Problem
Converting machines face challenges in automating the change of rewinding coils and managing delicate or brittle materials, leading to interruptions and reduced productivity.
Innovation Solution
A converting machine with an automated system that includes a loading unit, an accumulation unit, and a winding unit with a revolving disc, feeding roller, movable accompanying member, and cutting member, all actuated by electric or pneumatic actuators, allowing for automatic coil changes and continuous processing without human intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual intervention is used for coil change, then the process can be completed with simple equipment, but productivity decreases and interruptions increase
Solution Approach 1:
The system performs coil change automatically without human intervention. The carriage moves autonomously to position the new coil, the cutting member severs the strip automatically, and the accumulation unit feeds material continuously, enabling the machine to service itself during coil changes.
Solution Approach 2:
The accumulation unit stores a buffer of strip material in advance before the current coil is exhausted. This preliminary accumulation allows the system to switch to a new coil without interrupting the winding process, as the buffer material bridges the transition period.
2Reliability
If the machine processes delicate and brittle materials, then the end product quality is improved, but material breakage increases causing interruptions
Solution Approach 1:
The accumulation unit acts as a cushion buffer that absorbs the shock of coil changes and material transitions. By storing extra material in advance, it prevents sudden stops and restarts that could cause breakage in delicate materials, maintaining continuous gentle feeding.
Solution Approach 2:
The system maintains continuous material flow through the accumulation unit buffer during coil changes. The strip is fed continuously without interruption or stopping, preventing the start-stop cycles that cause breakage in brittle materials, thus maintaining both quality and productivity.
3Productivity
If a buffer section is arranged upstream, then coil change can occur without interrupting the process, but substantial human intervention is still required
Solution Approach 1:
The complete coil change sequence is automated: the carriage positions itself, the cutting member severs the strip automatically at the correct moment, and the system transitions to the new coil without human intervention. The buffer section works in conjunction with these automated elements to enable fully autonomous operation.
4Manufacturing precision
If the cutting member is positioned on the carriage, then precise crosswise cutting is achieved, but the device complexity increases
Solution Approach 1:
The cutting member is integrated into the existing carriage structure that already performs multiple functions (positioning, feeding, and cutting). By combining the cutting function with the carriage rather than adding a separate cutting device, the system achieves precise positioning without proportionally increasing overall complexity.
Data Source
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AI summary
The present invention relates to a converting machine, i.e., a machine for winding or unwinding a strip of material on coils, particularly configured to process a delicate material. In particular, the invention is directed to a machine (1) for converting coils of a material into smaller coils, comprising a loading unit (2) for loading a strip (N) of material into the machine (1), an accumulation unit (3) of the strip (N) being processed, and a winding unit (4) of the strip (N) on a winding shaft (5, 5') to form respective coils (B), characterized in that the winding unit (4) comprises: - a revolving disc (29), which supports two winding shafts (5, 5') of coils (B); - a feeding roller (30) of the strip (N) to a winding position; - a movable accompanying member (31) of the strip (N) and a cutting member (32) operatively associated with said feeding roller (30), wherein the feeding roller (30), the movable accompanying member (31), and the cutting member (32) are placed on a carriage (33), movable horizontally between at least one forward or operating position and a retracted or resting position; and wherein the movable accompanying member (31) and the cutting member (32) are hinged on the axis of the feeding roller (30) and are tiltable between a non-operating position and an operating position adapted to operate the crosswise cut of the strip (N) .