Independent Winding Modules for Continuous Web Processing
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Solution Overview
Problem
Conventional center and surface winders face issues with production interruptions due to core load faults or web breaks, limited control over roll bulk characteristics, and inefficiencies in producing high-speed rolled products with varying bulk levels without compromising quality or stability.
Innovation Solution
A system with independent winding modules that can engage in center winding, surface winding, or a combination of both, allowing for continuous operation even if one module fails, and featuring a core loading apparatus and product stripping mechanism to control roll bulk through adjustable nip pressure, tension, and mandrel torque.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional center or surface winders are used, then rolled products can be produced, but production must be shut down when core load faults or web break faults occur
Solution Approach 1:
The winder is divided into multiple independent winding modules (first winder module, second winder module, etc.), each capable of operating autonomously. When a fault occurs in one module, other modules can continue producing rolled products, eliminating production shutdowns and maintaining continuous operation.
2Manufacturing precision
If center winding is used, then soft-wound higher bulk rolled products can be produced efficiently, but control over roll bulk is limited and excessive web tension is required for high bulk products
Solution Approach 1:
The system dynamically switches between center winding and surface winding modes, or combines both methods, to control roll bulk. This dynamic approach allows precise control over bulk characteristics without requiring excessive web tension, thereby avoiding undesirable increases in product strength.
3Manufacturing precision
If surface winding is used to produce high roll bulk products, then contact pressure must be decreased, but this decreases friction and results in loss of control and log instability
Solution Approach 1:
The invention merges center winding and surface winding into a hybrid system. The center winding component provides stable log formation and control, while the surface winding component enables high roll bulk production. This combination achieves both high bulk and stability without the drawbacks of either method alone.
4Ease of repair
If conventional winders are used, then rolled products can be produced, but maintenance requires shutting down the entire machine
Solution Approach 1:
The winder is segmented into independent modules that can be maintained separately. When one module requires maintenance, other modules continue operating, allowing repairs without production interruption and significantly improving ease of repair.
5Device complexity
If single winding module is used, then machine structure is simpler, but any fault causes complete production shutdown
Solution Approach 1:
The system uses multiple independent winding modules instead of a single module. This segmentation increases device complexity but provides redundancy, ensuring that a fault in one module does not cause complete production shutdown, thereby improving reliability.
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
Enables the production of rolled products with a wide range of bulk characteristics at high speeds without interruptions, improving efficiency and reducing waste by allowing individual module maintenance without halting the process.
Implementation Method 1
a mandrel that is rotated onto which the web is wound to form the rolled product
Implementation Method 2
the web is wound onto the core via contact and friction developed with rotating rollers
Implementation Method 3
A nip is typically formed between two or more co-acting roller systems
Data Source
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AI summary
A winder for winding a web to produce a rolled product is provided. The winder includes a web transport apparatus that is used for conveying the web. Also included in one exemplary embodiment is a plurality of independent winding modules. The winding modules are independently positioned to independently engage the web as the web is conveyed by the web transport apparatus. The winding modules may be configured to wind the web to form a rolled product by center winding, surface winding, and combinations of center and surface winding. The winding modules are structurally and operationally independent of one another where if one module is disabled, another may still operate to produce the rolled product without shutting down the winder.