Flexible Drive Core Engagement for Rewinding Vibration Control
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Solution Overview
Problem
Rewinding systems face challenges in producing low firmness, large diameter products at high speeds without excessive log vibration, which leads to winding defects and operational issues, and require robustness to handle variations in web material properties without specialized skills.
Innovation Solution
The use of a winding nest configuration comprising a winding drum and a belt, where the belt's surface velocity is varied cyclically relative to the winding drum's velocity, and the distance between the belt and drum is adjusted to control log advancement, winding, and discharge, with rider rolls and core chucks to manage core engagement and reduce vibration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If center winders are used to wind low firmness, high bulk logs, then winding effectiveness is improved, but web tension control limitations cause frequent web blowouts and tearing at high speeds
Solution Approach 1:
A core engagement assembly with a chuck is introduced as an intermediary device between the mandrel and the core. The chuck engages the core end and provides positive rotational drive, acting as a mediator that transfers torque efficiently while allowing independent control of core rotation speed and web tension, thereby preventing web blowouts and tearing during high-speed winding of low firmness logs
2Reliability
If surface winders are used to wind high firmness, low bulk logs, then winding effectiveness is improved, but excessive log vibration occurs at high speeds causing winding defects and operational problems
Solution Approach 1:
The core engagement assembly with chuck acts as an intermediary that provides positive rotational drive to the core, stabilizing log rotation and reducing excessive vibrations during high-speed winding. The chuck's direct engagement with the core end eliminates slip and ensures controlled rotation, preventing winding defects while maintaining high winding effectiveness
Solution Approach 2:
The patent addresses vibration control by providing positive rotational drive through the chuck engagement assembly. This mechanical coupling stabilizes the core rotation and reduces excessive log vibrations that occur during high-speed surface winding, thereby preventing operational problems and winding defects
3Productivity
If center winders operate at high cycle rates, then productivity is improved, but time required to decelerate logs and remove finished logs from mandrels increases cycle time
Solution Approach 1:
The chuck is designed to be quickly disengaged from the core end after winding completion. This extraction of the engagement mechanism allows rapid log removal without the time-consuming process of gradually decelerating and manually removing logs from the mandrel, thereby reducing cycle time and increasing productivity
4Productivity
If surface winders produce low firmness, large diameter products at high speeds, then productivity is improved, but excessive log vibration causes winding defects and operational failures
Solution Approach 1:
The core engagement assembly with chuck serves as an intermediary device that provides positive rotational drive to the core during high-speed winding of low firmness, large diameter logs. This direct engagement stabilizes core rotation, reduces excessive log vibrations, and prevents winding defects while maintaining high productivity
Data Source
AI summary
A core end engagement assembly is provided for a rewinding machine. The core end engagement assembly is configured to engage an end of the core and transmit rotational movement to the core during winding of the web material about the core. The assembly may include a drive housing. A chuck may project from a first end of the drive housing and may be configured to engage the end of the core. A first actuator may reciprocate the drive housing along a central axis of the core between an engagement and disengagement position of the chuck relative to the core. A second actuator may be mounted on the drive housing. The second actuator may be configured and adapted to move the chuck between release and hold positions. A flexible drive shaft operatively connects with and rotationally drives the chuck.