Film Web Spool Changeover With Partial Cut to Prevent Creasing
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Solution Overview
Problem
In the process of winding a film web onto multiple reels, the incomplete severance of the film web results in poor winding quality and potential malfunctions due to the remaining portion springing onto the first reel, especially when the web is under tension, leading to creasing and wrapping issues.
Innovation Solution
The film web is partially cut transversely with an incomplete separation edge, leaving an uncut section connected, which is then stretched and torn or cut off later, ensuring the new end remains under tension and can be wound without defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the film web is completely cut before the first reel, then the separation is complete and the new web start can be formed, but the remaining portion springs onto the first reel causing poor winding quality and creasing
Solution Approach 1:
The cutting device performs a preliminary incomplete cut that creates a separation edge defining the end of the film web, but leaves an uncut section to maintain connection. This preliminary action prevents the harmful springing effect while still establishing the web end position, resolving the contradiction between complete separation and maintaining tension control
Solution Approach 2:
The cutting process is segmented into two stages: first creating an incomplete separation with a separation edge, then later completing the separation by tearing or cutting the uncut section. This segmentation allows the system to achieve both complete separation and tension maintenance at different times in the process
2Productivity
If the film web is under tension before reaching the first reel, then the web can be wound efficiently, but sudden severance causes the remaining portion to spring onto the reel
Solution Approach 1:
The incomplete cut is performed as a preliminary action while the web is under tension, allowing efficient winding to continue. The uncut section acts as a buffer that prevents sudden springing, maintaining process stability while preserving winding efficiency
Solution Approach 2:
The uncut section serves as a cushioning element that absorbs the sudden release of tension when the web is severed. This beforehand cushioning prevents the harmful springing effect while allowing the web to remain under tension during the winding process
3Ease of operation
If the film web is completely separated, then the new web start is clearly defined, but the end of the film web cannot be easily located and removed
Solution Approach 1:
The incomplete cut creates a visible separation edge that distinguishes the web end from the bulk material. This visual change makes the web end easily locatable and removable, improving ease of operation while maintaining clear separation definition
Solution Approach 2:
The separation process is divided into creating a defined separation edge followed by complete separation of the uncut section. This segmentation provides both a clear definition of the web end and easy accessibility for removal operations
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
This method ensures a high-quality winding process by maintaining tension on the film web end, preventing creasing and facilitating easy unwinding, particularly effective with thin and sticky films.
Implementation Method 1
the film web is stretched in the uncut area at least until at least one cutting edge rests substantially on the first reel
Data Source
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AI summary
The invention relates to a method for successively winding a film web onto a plurality of spools, wherein the film web is wound to form a first spool, and a tube and/or winding shaft for forming a subsequent second spool and the film web are moved closer to one another and/or are brought into contact with one another upstream of the first spool. The film web is cut, and thus an end of the film web is produced, which end is wound onto the first spool, and a new start of the film web is produced, which is wound onto the second tube. In order to cut the film web, the film web is cut partially in the transverse direction, at least one cut edge and at least one uncut region remaining in the transverse direction, the uncut region being subsequently torn off or cut off.