Disc Blade Handling for Continuous Log Cutting Machines
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Solution Overview
Problem
The existing cutting machines for logs of wound web material, such as tissue paper, face challenges in replacing disc-shaped cutting blades, which is a dangerous and time-consuming process, leading to production losses and quality issues due to machine shutdowns and handling difficulties.
Innovation Solution
A method and apparatus for cutting logs using a cutting machine with a feeding path and a cutting head equipped with a disc-shaped cutting blade that moves cyclically, featuring a storage unit for blades and a handling member to replace worn blades without stopping the machine, allowing for quick and safe blade changes, and optionally using automatic grinding systems to maintain blade sharpness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual replacement of disc-shaped cutting blades is used, then blade replacement can be performed, but the operation is dangerous and time-consuming requiring 20-30 minutes shutdown
Solution Approach 1:
The system performs automatic blade replacement using a robot manipulator that autonomously removes worn blades and installs new blades from a storage unit, eliminating the need for manual intervention and enabling continuous operation without 20-30 minute shutdowns
Solution Approach 2:
A robot manipulator serves as an intermediary between the blade storage unit and the cutting head, performing the dangerous blade replacement task automatically to protect operators while reducing replacement time to minimal interruption
2Ease of manufacture
If disc-shaped cutting blades are used, then cutting of logs can be performed, but the blades are bulky and heavy making them difficult to handle
Solution Approach 1:
The automated blade replacement system handles the bulky and heavy disc-shaped blades using a robot manipulator with appropriate grippers, eliminating manual handling difficulties while maintaining the effective cutting capability of the disc-shaped blade design
3Manufacturing precision
If frequent blade replacement is required, then cutting quality can be maintained, but production losses increase due to machine shutdowns
Solution Approach 1:
The automated blade replacement system enables continuous production by performing blade changes during operation or with minimal interruption, preventing the 20-30 minute shutdowns that cause production losses while maintaining cutting quality through timely blade replacement
Solution Approach 2:
The system automatically manages blade replacement timing and execution, ensuring blades are replaced before quality degrades while minimizing production interruption, thus maintaining both cutting quality and production continuity
4Ease of repair
If manual blade replacement is performed in narrow space, then blade replacement can be completed, but the risk of operator injury increases due to sharp edges
Solution Approach 1:
The robot manipulator performs the blade replacement task autonomously in the narrow space around the cutting head, eliminating operator exposure to sharp blade edges and significantly reducing injury risk while completing the replacement capability
Solution Approach 2:
The robot manipulator acts as an intermediary that safely handles the sharp disc-shaped blades in the confined space, removing the operator from the hazardous environment while maintaining the ability to perform blade replacements
Data Source
AI summary
The cutting machine for cutting logs of web material, includes a cutting head arranged along the feeding path of the logs. The cutting head includes a coupling for a disc-shaped cutting blade and is designed to impart the disc-shaped cutting blade a rotary motion around the axis thereof and a cyclic movement to cut the logs into single rolls, and to allow the logs to move forward along the feeding path. The machine also includes a store unit for disc-shaped cutting blades associated with the cutting head. A handling member is provided to remove a worn disc-shaped cutting blade from the cutting head and replace the worn disc-shaped cutting blade with a new disc-shaped cutting blade taken from the store unit.