Film Rewinder Laser Telemeter Edge Misalignment Detection

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Solution Overview

Problem

Existing film rewinder machines face challenges in accurately detecting and correcting side edge misalignments during the rewinding process, particularly with lightweight stretchable materials, leading to telescoping and uneven rolls, which requires skilled operators and is time-consuming.

Innovation Solution

Incorporating a laser telemeter system that projects a laser beam perpendicular to the rewinder shaft to detect edge misalignments and automatically adjust operational parameters to maintain edge alignment, ensuring consistent roll quality.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If manual detection by experienced operators is used to detect edge misalignments, then detection capability relies on operator expertise, but the process is time-consuming and produces inconsistent results

Engineering Contradiction:

Improveedge misalignment detection accuracyVSAvoiddetection time

Core Design Contradiction:

Measurement precisionVSLoss of time

Solution Approach 1:

The patent replaces manual visual inspection by operators with an automated optical detection system using laser beams and sensors. The system projects laser beams perpendicular to the film band edges and detects misalignments automatically, eliminating dependence on operator expertise and reducing detection time while maintaining high precision.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The detection system enables the machine to automatically monitor and detect edge misalignments without human intervention. The automated system continuously measures film position and provides real-time feedback, allowing the machine to self-regulate and maintain alignment precision throughout the rewinding process.

Inventive Principle:

Principle #25Self-service

2Force

If pulling force is increased to unwind lightweight stretchable materials, then sufficient tension is achieved, but the film band weaves laterally and tension becomes uneven

Engineering Contradiction:

Improvepulling forceVSAvoidedge alignment precision

Core Design Contradiction:

ForceVSManufacturing precision

Solution Approach 1:

The patent implements a feedback control system where laser beams continuously monitor the position of film band edges during unwinding and rewinding. The detection system provides real-time feedback on misalignments, allowing the control system to adjust pulling forces and rewinding speed dynamically, preventing lateral weaving and tension unevenness while maintaining sufficient tension for lightweight materials.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The system dynamically adjusts operational parameters including pulling force and rewinding speed based on real-time detection of film tension and position. This dynamic control prevents over-spinning and lateral weaving by coordinating force application with the changing diameter of the unwinding roll, maintaining edge alignment precision throughout the winding operation.

Inventive Principle:

Principle #15Dynamics

3Measurement precision

If automated detection system with laser telemeter is implemented, then edge misalignment detection precision is improved, but device complexity increases

Engineering Contradiction:

Improveedge misalignment detection precisionVSAvoiddetection system complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent replaces complex manual inspection procedures with a relatively simple automated optical system using laser beams and position sensors. The laser telemeter system provides precise edge alignment detection through optical means, achieving high measurement precision with a compact and manageable device configuration that integrates seamlessly into the existing rewinding machine.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The system precisely detects edge misalignments and automatically adjusts operational parameters to prevent telescoping, reducing operator dependency and ensuring uniform roll edges, enhancing productivity and roll quality.

Implementation Method 1

at least one laser telemeter configured to project a laser beam towards the at least one rewinder shaft

Methodology Applied

Scientific EffectLight reflection: Reflection

Data Source

PatentEP4086211B1A film rewinder machine comprising a misalignment detector and misalignment detection method in a film rewinder machine

Publication Date: 2023.08.23 COMEXI GRP IND

Figure 1A~1B
Figure 2A~2B
Figure 3A~3B

AI summary

Film rewinder machine with misalignment detector comprising a rewinder station (10), connected to a conveyance path (3) of a film band (1), including at least one rewinder shaft (11a, 11b) configured to support and rotate at least one core to wind said at least one film band (1) around the core forming a roll (4); wherein the machine further comprises at least one laser telemeter (20) configured to be placed in a measurement position and to project a laser beam directed towards the at least one rewinder shaft in a plane perpendicular to the at least one rewinder shaft, at an offset distance in a transversal direction over at least one predefined edge position, the laser telemeter (20) being configured to detect any edge misalignment in the transversal direction (TD) equal to or bigger than said offset distance.