Coreless Rewinding Machine Airflow Winding Control
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Solution Overview
Problem
Conventional coreless paper roll rewinding machines face issues with unstable force application, uneven tightness leading to core portion wrinkling, increased structural complexity, and surface indentations due to the reliance on winding assisting plates and precise roller gap control.
Innovation Solution
A coreless paper roll rewinding machine that uses air flow to assist the start of winding by employing parallel rewinding rollers with air flow channels and suction holes, eliminating the need for a winding assisting plate and allowing a stable, even force application without changing the roller gap, thus preventing wrinkling and reducing structural complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a winding assisting plate is used to support the paper roll at the preliminary stage of rewinding, then the start of winding can be achieved, but the force applied on the paper roll becomes uneven causing core portion wrinkling
Solution Approach 1:
The patent replaces the mechanical winding assisting plate with a pneumatic system consisting of air blowing devices and air suction devices. The air blowing device blows air upward to lift the paper web, while the air suction device creates negative pressure to hold the lifted paper, eliminating mechanical contact and achieving uniform force distribution across the paper roll surface.
Solution Approach 2:
The patent employs pneumatic principles by using air blowing devices to generate upward airflow that lifts the paper web, and air suction devices to create negative pressure fields that hold the paper. This pneumatic system replaces mechanical support structures and provides uniform force application without causing localized deformation or wrinkling.
2Ease of operation
If the roller gap is changed during the process from start of winding to rewinding, then the winding can be initiated, but the force applied on the paper roll becomes unstable
Solution Approach 1:
The patent replaces the mechanical roller gap adjustment system with a pneumatic control system. The air blowing and air suction devices can be independently controlled to provide stable lifting and holding forces without requiring physical changes to the roller gap, thereby maintaining force stability throughout the winding process.
Solution Approach 2:
The patent changes the control parameter from mechanical roller gap dimension to pneumatic pressure parameters. By controlling the air blowing pressure and air suction negative pressure independently, the system achieves both the ability to initiate winding and maintain stable force application without mechanical adjustments.
3Productivity
If the rewinding lower roller moves while rotating at high speed, then the winding can be performed, but the structural complexity and manufacturing cost increase
Solution Approach 1:
The patent replaces the complex mechanical system requiring the rewinding lower roller to move with a stationary roller configuration. The air blowing and air suction devices provide the necessary forces to initiate and maintain winding on a fixed lower roller, eliminating the need for complex movement mechanisms while maintaining high-speed operation capability.
4Reliability
If the comb shape front end of the winding assisting plate is inserted into a ring groove on the rewinding lower roller, then the winding can be started, but significant indentations are left on the surface of the paper roll
Solution Approach 1:
The patent replaces the mechanical comb-shaped assisting plate that physically contacts and indents the paper roll with a pneumatic system using air blowing and air suction devices. This eliminates mechanical contact during the critical winding initiation phase, preventing surface indentations while reliably starting the winding process through controlled airflow.
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 air flow assisted rewinding machine ensures stable and even force application, prevents core portion wrinkling, simplifies the mechanism, and improves the appearance of the paper roll by eliminating surface indentations.
Implementation Method 1
an air suction cover (6) is arranged at one end of the rewinding upper roller (1)... when a certain row of the air suction holes (5) on the surface of the rewinding upper roller (1) is gradually closing towards the roller gap... the air flow channel (4) in the roller body, which is interconnected with the row of air suction holes (5), is rotated to a region where it interconnects with an exhaust opening of the air suction cover (6)
Implementation Method 2
an air pipe is arranged above the rewinding lower roller to blow air downwards
Implementation Method 3
the paper is further bent under the effect of friction of the rewinding lower roller
Data Source
Figure 1~2
Figure 3~6
Figure 7~8
AI summary
A coreless paper roll rewinding machine using air flow to assist starting winding is mainly characterized in that: an air pipe (11) blowing air downwards is arranged above a rewinding lower roller (2); the roller gap (M) between a rewinding upper roller (1) and the rewinding lower roller (2) is no more than 10mm; a plurality of air flow channels (4) are distributed in the roller body of the rewinding upper roller (1); a plurality of sets of air suction holes (5) are formed on the surface of the roller body; each set of the air suction holes (5) are interconnected with each air flow channel (4) formed in the roller body; an air suction cover (6) is arranged in the position close to the end part of the rewinding upper roller (1); and each air flow channel (4) formed in the roller body is interconnected with or disconnected with the air suction holes of the air suction cover (6) in turn along with rotating of the rewinding upper roller (1). The coreless paper roll rewinding machine neither needs to depend on the support of a winding assisting plate nor needs to change the roller gap between the rewinding upper roller (1) and the rewinding lower roller (2) during the whole process from starting rewinding to finishing rewinding.