Dual Position Winder for Continuous Web Processing

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Solution Overview

Problem

Converting and printing machinery faces challenges in transferring webs of material to new cores without stopping the winding process, while maintaining consistent winding direction and avoiding damage to the web, as existing solutions are either costly, complex, or inefficient in terms of space and labor.

Innovation Solution

A winder system with two stationary winding positions and a roll positioning assembly that allows for continuous winding by moving the web upstream and installing a new core without stopping, ensuring consistent winding direction and reducing the need for expensive or space-intensive equipment.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If a single winder position is used with manual roll change, then device complexity is reduced, but productivity decreases due to stoppage time and labor intensity

Engineering Contradiction:

Improvewinding continuityVSAvoidwinder structure

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The winder is divided into two separate winding positions (first and second positions) that can operate independently. This segmentation allows one position to continue winding while the other undergoes roll change, eliminating stoppage time and maintaining continuous productivity without requiring complex automated mechanisms at a single position.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Two winding positions are combined into a single winder system sharing common support structures, drive mechanisms, and control systems. This merging provides the productivity benefits of continuous operation while avoiding the full complexity of two completely separate winders, as the shared components reduce overall device complexity.

Inventive Principle:

Principle #5Merging (Combining)

2Object-affected harmful factors

If surface winder with driven roller is used, then web damage is reduced, but manufacturing cost increases significantly

Engineering Contradiction:

Improveweb stressVSAvoidsystem cost

Core Design Contradiction:

Object-affected harmful factorsVSEase of manufacture

Solution Approach 1:

Instead of driving the winding roll from the outside through web contact (surface winder method that causes stress), this invention drives the winding roll from the inside through the core. This inverted approach eliminates web stress during roll driving while using simpler, less expensive mechanical components compared to surface winder systems.

Inventive Principle:

Principle #13The other way round (Inversion)

3Object-affected harmful factors

If turret winder is used, then web damage is minimized, but device complexity and space requirements increase

Engineering Contradiction:

Improveweb stressVSAvoidmoving parts

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The invention extracts and eliminates the complex turret assembly with multiple rotating spindles and moving parts. Instead, it uses fixed winding positions with stationary support structures, maintaining the benefit of direct core driving while removing the complexity and space requirements of turret mechanisms.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The system uses dynamically switchable winding positions where the web can be redirected between first and second positions. This dynamic switching provides the flexibility needed for continuous operation without requiring the mechanical complexity of rotating turrets, as the positions are fixed but selectively engaged.

Inventive Principle:

Principle #15Dynamics

4Productivity

If accumulator is used for roll change, then productivity is maintained, but device complexity and space requirements increase

Engineering Contradiction:

Improvewinding continuityVSAvoidfloor space

Core Design Contradiction:

ProductivityVSArea of stationary object

Solution Approach 1:

Instead of using an accumulator that extends horizontally and requires significant floor space, this invention uses vertical arrangement of winding positions with the web traveling upward between them. This dimensional change allows continuous operation while minimizing floor space requirements.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Data Source

PatentUS20240317525A1Dual position automatic winder

Publication Date: 2024.09.26 NEW ERA CONVERTING MACHINERY INC

AI summary

A winder for winding process webs on roll cores may include a first winding position configured for rotatably securing a first roll core and rotating the first roll core in a first rotational direction. The winder may also include a second winding position configured for rotatably securing a second roll core parallel to the first roll core and rotating the second roll core in the first rotational direction. The winder may also include a roll positioning assembly configured to move a portion of the web upstream of the second winding position from a first side of the first winding position to a second side of the first winding position.