Log roll manufacturing apparatus
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Solution Overview
Problem
The existing log roll manufacturing apparatus for toilet paper and kitchen roll paper has lower product efficiency for one-ply products compared to two-ply products, as it underutilizes the base-paper feeders when producing one-ply rolls, leading to inefficiencies in the manufacturing process.
Innovation Solution
The apparatus includes a base-paper delivery unit that feeds multiple-layer base paper from multiple parent rolls, a processing-winding unit with sub-units, a base-paper separating unit, and a guide unit to separate and direct the base paper for efficient winding, allowing for simultaneous production of one-ply or multi-ply log rolls across multiple units.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a one-ply log roll is manufactured using a winder equipped with two base-paper feeders, then the apparatus can produce two-ply products efficiently, but the product efficiency for one-ply products decreases because only one feeder is utilized
Solution Approach 1:
The patent divides the multi-layer base paper into separate single-layer sheets using a base-paper separating unit. This segmentation allows each layer to be independently directed to different processing-winding units, enabling one-ply log rolls to be produced using only one base-paper feeder while two-ply products can utilize both feeders simultaneously.
Solution Approach 2:
The patent introduces a base-paper guide unit that dynamically directs separated base paper sheets to different processing-winding units based on production requirements. This dynamic routing system allows flexible allocation of base paper layers to main or sub processing-winding units, optimizing feeder utilization for both one-ply and two-ply product manufacturing.
2Productivity
If multiple parent rolls are fed simultaneously to produce multi-ply log rolls, then productivity increases, but device complexity increases due to additional base-paper feeders and handling mechanisms
Solution Approach 1:
The base-paper separating unit and base-paper guide unit serve multiple functions: they enable both one-ply and two-ply product production from the same apparatus, allow flexible routing of base paper layers to different processing-winding units, and maintain compatibility with varying production requirements. This multi-functionality reduces the need for separate dedicated systems for different product types.
Solution Approach 2:
The base-paper separating unit acts as an intermediary between the base-paper feeders and processing-winding units. It receives multi-layer base paper, separates it into individual layers, and passes them to the guide unit for distribution. This intermediary structure simplifies the overall system by centralizing the separation function rather than requiring complex individual feeding mechanisms for each processing unit.
3Adaptability or versatility
If sub processing-winding units are added to the apparatus, then flexibility in production is improved, but device complexity and initial investment increase
Solution Approach 1:
The base-paper guide unit provides dynamic routing capability, directing separated base paper sheets to either the main processing-winding unit or sub processing-winding units based on real-time production requirements. This dynamic allocation system maximizes the utilization of available processing capacity and enables flexible switching between one-ply and two-ply production modes.
Solution Approach 2:
The base-paper separating unit performs preliminary separation of base paper layers before they reach the processing-winding units. This preliminary action prepares the base paper for flexible distribution to different processing units, enabling the system to adapt to varying production demands without requiring complex real-time separation mechanisms at each processing unit.
Data Source
AI summary
A log roll can be efficiently manufactured in a log roll manufacturing apparatus. When yet-to-be-wound base paper constituted of stacked sheets of first base paper and second base paper fed from first and second parent rolls is supplied to a main processing-winding unit, if a winder capable of manufacturing a two-ply log roll and including a sub processing-winding unit is to manufacture a one-ply log roll by using the main processing-winding unit, the yet-to-be-wound base paper constituted of the stacked sheets of the first base paper and the second base paper is separated into first separated yet-to-be-wound base paper and second separated yet-to-be-wound base paper by a base-paper separating unit. Then, one-ply log rolls are simultaneously manufactured by using the main processing-winding unit supplied with the first separated yet-to-be-wound base paper and the sub processing-winding unit supplied with the second separated yet-to-be-wound base paper.