Folding Roll Vacuum Distribution for Energy-Efficient Paper Interfolding
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Solution Overview
Problem
Existing paper converting machines are complex, large, and energy-intensive, with high energy consumption due to the need for suction-type cutting and folding rolls. These machines are also limited in their ability to produce different types of products, as the rolls are designed for specific panel lengths.
Innovation Solution
A folding or interfolding unit with counter-rotating rolls equipped with suction holes, vacuum generation, and selective vacuum distribution to adhere sheets to the rolls. This unit includes associated cutting devices with counter-blades and a separation mechanism to efficiently fold and separate sheets without the need for large, complex machinery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If suction-type folding rolls are used to hold sheets during folding, then the folding process can be automated and continuous, but the energy consumption increases significantly due to the need for continuous vacuum generation
Solution Approach 1:
The vacuum distribution device activates suction holes periodically rather than continuously, creating alternating zones of suction and non-suction on the folding roll surface. This periodic action allows sheets to be held during folding then released for separation, eliminating the need for continuous vacuum generation and significantly reducing energy consumption while maintaining automation.
2Reliability
If folding rolls with fixed circumference are used, then the structure is simple and reliable, but the machine cannot produce different panel lengths without replacing the rolls
Solution Approach 1:
The invention introduces a vacuum distribution device that can dynamically control which zones of the folding roll surface are active, effectively allowing the same physical roll to function with different panel lengths by adjusting the pattern and positioning of active suction holes, thereby providing flexibility without changing the roll structure.
Solution Approach 2:
The system changes the operational parameters of the folding roll by controlling the vacuum distribution pattern - the angular position, activation timing, and coverage area of suction holes can be adjusted to accommodate different panel lengths, transforming a fixed-structure roll into a variable-parameter system.
3Productivity
If both cutting rolls and folding rolls with suction holes are used, then the machine can perform all necessary operations, but the device complexity and size increase significantly
Solution Approach 1:
The invention merges the sheet retention function traditionally provided by separate suction-type folding rolls with the existing cutting roll structure by adding a vacuum distribution device to the cutting roll. This integration eliminates the need for separate suction-type folding rolls, reducing device complexity while maintaining full production capability.
Solution Approach 2:
The cutting roll is transformed into a multi-functional component that performs both cutting and sheet retention functions through the added vacuum distribution system, allowing a single component to replace what would traditionally require multiple separate components, thereby simplifying the overall machine structure.
4Device complexity
If separator members are positioned within the encumbrance of folding rolls, then the separation function can be integrated, but the separator members interfere with the counter-blades during operation
Solution Approach 1:
The separator members are positioned in a different spatial dimension - on the peripheral surface of the folding roll rather than within the internal encumbrance. This allows the separators to engage with sheets for separation while maintaining clear clearance from the counter-blades that operate at different radial positions, eliminating interference while preserving integration.
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 solution enables a compact, energy-efficient paper converting machine that can operate at high speeds while maintaining product quality, and allows for the production of various types of interfolded products without the need for extensive machine reconfiguration.
Implementation Method 1
a vacuum generation device configured to produce a predetermined vacuum degree; a vacuum distribution device configured to selectively put into pneumatic communication said vacuum generation device with at least a row of said plurality of rows of suction holes
Data Source
Figure 1~2
Figure 3~4
Figure 5A
AI summary
A folding, or interfolding, unit, (100) for folding, or interfolding, a first and a second plurality of sheets of paper (105a, 105b) in a machine for converting paper, comprises a first and a second folding, or interfolding, counter-rotating rolls (1a, 1b) configured to rotate about a respective longitudinal rotational axis (110a, 110b) and providing a plurality of suction holes (11a, 11b, 12a, 12b). A vacuum generation device and a vacuum distribution device (40a, 40b) are, furthermore, provided for selectively putting into pneumatic communication the vacuum generation device with at least a row of the aforementioned suction holes (11a, 11b, 12a, 12b). The folding, or interfolding, unit, (100) comprises, furthermore, a first and a second cutting device (60a, 60b) providing, respectively, at least a first and a second cutting blade (65a,65b) which cooperates with a first and a second plurality of counter-blades (5a, 5b) distributed along the folding, or interfolding rolls (1a, 1b) in order to cut a first and a second web of paper (101a, 101b), in the first and in the second plurality of sheets (105a, 105b).