Automatic Disc Blade Change for Wound Web Log Cutting
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing cutting machines for logs of web material, such as tissue paper, face challenges in efficiently replacing disc-shaped cutting blades, which are hazardous and time-consuming, leading to production losses and quality issues due to machine shutdowns and potential operator risks during blade replacement.
Innovation Solution
A method and apparatus for automatically handling and replacing disc-shaped cutting blades using a handling member that installs and removes blades from a storage unit, allowing for quick and safe replacement without moving the cutting head, and optionally using two storage units and handling members to streamline the process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual replacement of disc-shaped cutting blades is performed, then the cutting machine can be maintained and continued to operate, but the replacement process is time-consuming (20-30 minutes) and dangerous for operators
Solution Approach 1:
The system uses an automatic blade replacement device that performs the replacement operation autonomously without requiring manual intervention. The device includes a gripper mechanism that automatically grasps, removes, and installs cutting blades, eliminating the need for operators to manually handle sharp blades and reducing replacement time from 20-30 minutes to a few seconds.
Solution Approach 2:
The manual mechanical operation of blade replacement is substituted with an automated mechanical system. The replacement device uses a gripper actuated by a piston-cylinder mechanism to automatically perform the replacement, replacing the manual mechanical action with an automated mechanical system that is both safer and faster.
2Manufacturing precision
If disc-shaped cutting blades are frequently replaced due to wear, then cutting precision is maintained, but production continuity is disrupted due to lengthy replacement procedures
Solution Approach 1:
The system maintains a stock of pre-prepared cutting blades in a magazine or storage unit. When a blade needs replacement, the automated device immediately retrieves a fresh blade from storage and installs it, eliminating the need for manual preparation and reducing downtime. The preliminary preparation and storage of replacement blades ensures production continuity.
Solution Approach 2:
The automated blade replacement system performs the entire replacement operation autonomously, including retrieving the next blade from storage, removing the worn blade, and installing the fresh blade. This self-service capability ensures that cutting precision is maintained through timely blade replacement without disrupting production flow.
3Ease of manufacture
If the cutting machine is stopped for blade replacement, then blade maintenance can be performed, but upstream machines cannot work continuously and production is lost
Solution Approach 1:
The automated blade replacement device enables the cutting machine to maintain continuous operation by performing blade replacements so quickly that the cutting process can resume immediately. The system uses a piston-cylinder mechanism to rapidly actuate the gripper, which grasps and replaces blades in seconds, ensuring that upstream machines continue to operate without interruption and production is not lost.
Solution Approach 2:
The manual blade replacement process, which required stopping the machine for 20-30 minutes, is replaced by an automated mechanical system that performs the same function in seconds. This substitution of manual mechanical operation with automated mechanical action eliminates production losses and maintains continuous utilization of upstream machines.
4Ease of operation
If operators manually access the cutting head for blade replacement, then blade replacement can be performed, but operator safety is compromised due to sharp edges and narrow access spaces
Solution Approach 1:
The automated blade replacement device performs the replacement operation without requiring operator access to the cutting head area. The device includes a gripper mechanism that automatically grasps and removes blades, eliminating the need for operators to manually handle sharp blades in narrow, difficult-to-access spaces, thereby completely removing the injury risk associated with manual blade replacement.
Solution Approach 2:
The manual mechanical operation of blade replacement, which exposed operators to safety hazards, is substituted with an automated mechanical system. The replacement device uses a piston-cylinder actuated gripper to automatically perform the replacement, replacing the dangerous manual mechanical action with a safe automated mechanical system that requires no operator access to the cutting zone.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The cutting machine (1) for cutting logs (L) of web material, comprises a cutting head (5) arranged along the feeding path of the logs (L). The cutting head (5) comprises a coupling for a disc-shaped cutting blade (9) and is designed to impart the disc-shaped cutting blade a rotary motion around the axis thereof (B-B) and a cyclic movement to cut the logs (L) into single rolls (R), and to allow the logs to move forward along the feeding path. The machine also comprises a store unit (73) for disc-shaped cutting blades (9A-9E) associated with the cutting head (5). A handling member (71) is provided to remove a worn disc-shaped cutting blade (9A-9E) from the cutting head (5) and replace the worn disc-shaped cutting blade with a new disc-shaped cutting blade (9A-9E) taken from the store unit (73).