Automated Embossing Roller Handling via Bridge Crane
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Solution Overview
Problem
Existing paper converting plants face challenges in efficiently and safely moving embossing rollers for maintenance and replacement, lacking an automated and reliable handling system.
Innovation Solution
A system comprising a bridge crane with gripper-equipped arms, an embossing unit with locking and unlocking mechanisms, and a storing unit, where interface bars with axial constraints allow the bridge crane to safely and automatically move embossing rollers between the embossing unit and storage, preventing translation along their longitudinal axis.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If manual handling methods are used for embossing rollers, then flexibility in movement is maintained, but safety and automation are compromised
Solution Approach 1:
The patent introduces interface means as an intermediary component between the bridge crane grippers and the embossing rollers. These interface means include engagement structures that connect the crane to the rollers, enabling automated handling without requiring direct integration between the crane and roller surfaces. This mediator approach allows automation while keeping the system modular and manageable in complexity
Solution Approach 2:
The bridge crane with grippers is designed to perform multiple functions: handling embossing rollers during replacement operations, moving rolls of paper material, and potentially other material handling tasks in the paper converting plant. This multi-functionality reduces the need for specialized equipment for each task, achieving automation without proportionally increasing overall system complexity
2Productivity
If embossing rollers are stored without predefined positioning, then storage flexibility is maintained, but location tracking and retrieval efficiency are reduced
Solution Approach 1:
The patent implements a storing unit where embossing rollers are placed in predefined positions before being needed. The interface means and bridge crane system are configured to place rollers in specific predetermined locations during storage operations. This preliminary positioning enables efficient retrieval operations later, as the system knows exactly where each roller is located without requiring complex search or tracking mechanisms during retrieval
Solution Approach 2:
The patent replaces manual tracking and location identification methods with an automated control system that manages the bridge crane movements and interface means operations. The predefined storage positions are managed through control logic rather than manual record-keeping, substituting mechanical/manual systems with automated control to improve productivity without proportionally increasing physical system complexity
3Reliability
If embossing rollers are moved without axial constraints, then ease of loading is maintained, but roller stability and safety are compromised
Solution Approach 1:
The patent divides the handling system into distinct functional components: the bridge crane for movement, the grippers for holding, and the interface means with specific engagement structures. The axial constraints are provided by dedicated elements within the interface means that specifically address roller stability without affecting the overall ease of operation. This segmentation allows each component to be optimized for its specific function while working together as an integrated system
Solution Approach 2:
The interface means serve as an intermediary between the grippers and the embossing rollers, providing the axial constraints through engineered engagement structures. This intermediary component translates the gripping force into stable, constrained transport while maintaining ease of operation through its design that facilitates automatic engagement and disengagement. The mediator approach allows safety features to be integrated without making the operation more difficult
Data Source
AI summary
Paper converting plant, including means for producing logs of paper material starting from one or more paper webs fed by corresponding reels, an embossing unit, a bridge crane with arms provided with grippers, and a rewinder that produces logs using the webs coming from the embossing unit, wherein the embossing unit is arranged to be configured in a first use configuration in which one or more embossing rollers positioned inside it are stably locked to respective support means and a second removal configuration in which said one or more embossing rollers are disengaged from said support means and can be extracted from the embossing unit, the plant also includes a storing unit in which are stored one or more embossing rolls according to a predefined storage order such that each embossing roller occupies a predetermined position in the same storage unit, each embossing roller having a respective longitudinal axis.