Embossing Roller Storage Unit for Tissue Production
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Solution Overview
Problem
Existing embossing devices for tissue paper production are inefficient due to the complexity and slowness of replacing individual embossing rollers, which is necessary for changing production types or patterns, especially when switching between tip-to-tip and nested embossing techniques.
Innovation Solution
An embossing device with a vertically arranged storage unit for spare rollers and a transfer device that moves along crossbeams, allowing for easy access and automated replacement of rollers, including glue applicator rollers, to facilitate quick changes in embossing patterns and configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a plurality of interchangeable embossing rollers are fitted onto a rotating support or sliding supports, then multiple embossing patterns can be stored, but the device becomes complex and replacement of individual rollers is not permitted
Solution Approach 1:
The storage unit is divided into multiple independent horizontal seats, each capable of holding a single embossing roller. This segmentation allows individual roller replacement while maintaining the overall storage structure, resolving the contradiction between versatility and complexity.
Solution Approach 2:
The storage unit is arranged vertically with seats stacked at different heights, utilizing the vertical dimension to store multiple rollers without expanding the horizontal footprint. This dimensional change simplifies the replacement mechanism compared to horizontal arrangements.
2Area of stationary object
If embossing rollers are stored in a compact arrangement, then space is saved, but access to rollers and seats for replacement becomes difficult
Solution Approach 1:
By arranging seats vertically at different heights, the storage unit minimizes horizontal space occupation while maintaining easy vertical access to each roller. The vertical stacking allows operators to access rollers at different levels without interfering with each other.
Solution Approach 2:
Each horizontal seat is designed with local accessibility features, allowing individual rollers to be removed and replaced independently. The seats are positioned and structured to provide optimal access points for each roller location.
3Area of stationary object
If the storage unit is placed close to the embossing area, then space is saved, but rollers are more likely to get dirty from dust and detritus
Solution Approach 1:
The storage unit is extracted from the immediate embossing area and positioned laterally aside at a distance. This separation removes the stored rollers from the contaminated zone while the vertical arrangement keeps the overall footprint compact.
Solution Approach 2:
The storage unit utilizes the lateral and vertical space away from the embossing area, positioning itself in a clean zone while maintaining efficient use of overall device space through vertical stacking.
4Device complexity
If manual roller replacement is used, then the device remains simple, but replacement frequency and downtime increase
Solution Approach 1:
A transfer device acts as an intermediary mechanism between the storage unit and the embossing area. This automated transfer system enables rapid roller replacement without requiring complex manual operations, improving productivity while maintaining reasonable device complexity.
Data Source
AI summary
An embossing device (1) includes an embossing area in which are arranged at least: a first embossing roller (5); a second embossing roller (7;9); a first pressure roller (11) co-acting with the first embossing roller; and a second pressure roller (15) co-acting with the second embossing roller. The embossing device further includes a storage unit (51) configured for containing spare embossing rollers (55, 57, 59), for replacing one or the other of the embossing rollers (5, 7) in the embossing area. The storage unit (51) develops substantially vertically, with mutually superposed seats (53) for receiving embossing rollers (55, 57, 59, 5, 7).