Automatic Embossing Roller Exchange System with External Storage
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Solution Overview
Problem
Existing embossing machines face significant downtime and operational inefficiencies due to the manual and labor-intensive process of replacing and storing embossing rollers, which also leads to soiling and limited flexibility in roller sharing and maintenance.
Innovation Solution
An embossing assembly with side panels divided into fixed and movable portions allows for automatic disengagement and reengagement of rollers, combined with an automated winch system for easy replacement and storage, enabling compact machine design and seamless roller exchange between machines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual dismantling and reassembly is performed to replace embossing rollers, then accessibility to rollers is improved, but machine downtime increases significantly
Solution Approach 1:
The side panels are made movable rather than fixed, allowing them to be opened to provide accessibility to the embossing rollers. This dynamic configuration enables quick access without manual dismantling, resolving the contradiction between ease of operation and time loss.
Solution Approach 2:
The side panels are divided into movable and fixed portions, allowing the movable portion to be opened independently to access the rollers while the fixed portion remains in place. This segmentation enables partial disassembly for maintenance without requiring complete machine dismantling.
2Productivity
If embossing rollers are stored inside the machine in appropriate seats, then roller availability for quick change is improved, but machine dimensions increase considerably
Solution Approach 1:
The roller storage function is extracted from the main machine body and placed in external magazine systems. This allows the machine to maintain a compact footprint while still providing quick access to multiple rollers through external storage units that can be loaded during production.
3Ease of operation
If rollers are stored inside the machine close to the work zone, then accessibility for change is improved, but rollers get soiled and cannot be cleaned during production
Solution Approach 1:
The roller storage and cleaning functions are extracted from the work zone and placed in separate external magazines. Used rollers can be removed from the machine, cleaned externally, and stored in the magazine system, preventing contamination of the work area while maintaining quick replacement capability.
Solution Approach 2:
External magazine systems act as intermediaries between the machine and the rollers. The magazines provide a clean storage environment separate from the work zone, allowing rollers to be stored and exchanged without being exposed to contaminants in the production area.
4Productivity
If automated winch systems are used for roller replacement, then replacement speed is improved, but device complexity increases
Solution Approach 1:
The winch system is designed to automatically perform the roller replacement operation without requiring complex control systems or multiple operators. The automated winding and unwinding mechanism provides self-service functionality that simplifies the replacement process while maintaining productivity benefits.
Data Source
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AI summary
A description is given of an automatic change system of embossing rollers (4A, 4B) comprising an embossing machine (1) provided with an exchange station external thereto and a movable side panel with upper blocking means for said rollers attached integrally to said movable side panel, a rollers storage magazine and/or shuttle (80), an automatic bridge crane (61) provided with hooking means, where said bridge crane is apt to extract automatically at least one of said embossing rollers (4A, 4B) from said embossing machine (1) when in open configuration, to transfer said extracted roller into said exchange station (60) on said embossing machine (1), to take a first exchange roller from said roller storage magazine (80) to house it in said embossing machine in the position of said extracted roller, to transfer rollers onto a shuttle for the possible external use on other lines or for maintenance or for an external check without having to interrupt production.