Automatic Film Splicing Roll Transfer for Continuous Packaging
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Manual splicing of material film in continuous packaging processes is inefficient, leading to excessive downtime and disruption in production continuity.
Innovation Solution
A fully automatic material film splicing apparatus with an on-line feeding device and multiple splicing devices, utilizing a reciprocally movable splicing roller and guide roller system, along with a cutting and holding mechanism, to seamlessly splice new film to depleted film without stopping the system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual splicing is used to replace depleted material film, then the splicing operation can be performed, but the system must be stopped resulting in excessive downtime and reduced productivity
Solution Approach 1:
The system performs preliminary actions by preparing the splicing operation in advance before the material film is completely depleted. The splicing device is positioned and ready, and the transition between film rolls is initiated before the current roll is fully exhausted, thereby avoiding complete shutdown and reducing downtime.
Solution Approach 2:
The patent implements continuous operation by designing an automatic splicing mechanism that maintains the material film supply without interruption. The system switches between old and new film rolls seamlessly, ensuring the packaging process continues without stopping, thus eliminating downtime and maintaining productivity.
2Ease of operation
If manual splicing procedure is implemented, then new material film can be bonded to the on-line roll, but the process is complicated and inefficient requiring system shutdown
Solution Approach 1:
The splicing device operates autonomously without requiring manual intervention. The system automatically positions the splicing roller, applies adhesive, bonds the new film to the old roll, and completes the transition without human involvement, thereby simplifying the operation and maintaining high productivity.
Solution Approach 2:
The patent replaces the manual mechanical splicing process with an automated mechanical system. The splicing device uses a splicing roller with adhesive application and automated positioning mechanisms to perform the bonding operation, substituting human labor with automated machinery that is both simpler to operate and more efficient.
3Reliability
If the system is stopped for manual splicing, then the material film can be replaced, but production continuity is disrupted
Solution Approach 1:
The system initiates the splicing process in advance before the material film is completely depleted. The splicing device is positioned and the bonding process begins while there is still material film on the current roll, ensuring continuous supply and avoiding complete shutdown, thereby maintaining reliability with minimal interruption.
Solution Approach 2:
The automated splicing mechanism ensures continuous material film supply by seamlessly transitioning from the depleted roll to the new roll. The system maintains uninterrupted operation throughout the splicing process, preventing any complete shutdown and ensuring continuous production with minimal downtime.
Data Source
AI summary
A fully automatic material film splicing apparatus and splicing method, comprising: an on-line material film feeding device and at least two material film splicing devices; the on-line material film feeding device being configured to switch between working positions corresponding to the at least two material film splicing devices; each of the material film splicing devices being equipped with a material film roll machine, the material film roll machine continuously delivering a strip-shaped material film into subsequent mechanisms via the material film splicing device and the on-line material film feeding device; when a material film in use (referred to as an on-line material film) is depleted, the on-line material film feeding device transferring an end portion of the on-line material film to the next material film splicing device to splice a starting portion of a new material film with the end portion of the on-line material film.