Hybrid Winder System for Web Material Transfer
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Solution Overview
Problem
Current winding technologies lack a winder or rewinder capable of performing both center winding and surface winding, leading to issues such as crushing of embossments, smudging of images, winding log instability, and non-uniform product density, particularly when handling low-density and high-density web materials.
Innovation Solution
A hybrid winder system that uses a conveyor belt to transfer web material to adjustable winding spindles, allowing for both center winding and surface winding techniques, with adjustable contact and tension control to accommodate various web material densities and prevent embossment distortion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If surface winding is used to wind web material, then the winding process is simple and the web material can be wound onto the core, but the contact between web material and winding surfaces crushes embossments and smudges images
Solution Approach 1:
The patent introduces a non-contact transfer mechanism where the web material is transferred from a conveyor belt to the winding spindle without direct contact between the web material and the winding surface. This intermediary transfer method eliminates the crushing of embossments and smudging of images while maintaining the simplicity of the winding process.
2Manufacturing precision
If center winding is used to wind web material, then the web material can be wound without contact damage, but the system requires harder pull and tension application that causes Poisson lateral contraction and non-uniform winding
Solution Approach 1:
The patent employs a dynamic winding system where the winding spindle rotates at variable speeds during the winding process. The system automatically adjusts the winding speed and tension to maintain uniform winding density and prevent Poisson lateral contraction, while avoiding contact damage to the web material surface.
3Quantity of substance
If high tension is applied during winding of high-density web material, then the web material can be wound into high-density rolls, but the tension causes Poisson lateral contraction and non-uniform product density
Solution Approach 1:
The patent changes the winding parameters by using variable speed rotation of the winding spindle and dynamic tension control. This allows the system to achieve high-density rolls while maintaining uniform product density by preventing excessive Poisson lateral contraction through optimized tension management.
4Productivity
If tension is applied to perforated web material during winding, then the web material can be wound efficiently, but the tension causes the web material to rupture at perforations
Solution Approach 1:
The patent uses a non-contact transfer mechanism as an intermediary that allows efficient winding of perforated web material without applying excessive tension that would cause rupture at the perforations. The conveyor belt transfers the web material to the winding spindle minimalistically, preserving web material integrity.
5Device complexity
If a single winder type is used for all web materials, then the equipment is simple, but the system cannot accommodate both low-density and high-density products with different requirements
Solution Approach 1:
The patent designs a universal winder system that can handle both low-density and high-density web materials by combining non-contact transfer capability with variable speed rotation and dynamic tension control. This multi-functional system eliminates the need for separate winders for different product densities.
Data Source
AI summary
A process for winding a web material such as continuous webs or interleaved web segments into rolls is disclosed. The process disposes a web material on a conveyor belt. At least one winding spindle is disposed proximate the web material disposed upon the conveyor belt. The conveyor belt is adjusted relative to the at least one winding spindle. The web material is then transferred to the at least one winding spindle from the conveyor belt.