Log roll production device
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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 effectively, allowing for simultaneous production of one-ply and multi-ply log rolls across multiple processing units, thereby optimizing the use of parent rolls and increasing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If a one-ply log roll is manufactured using the toilet-paper manufacturing winder, then the base paper is wound by a longer product length (60m), but the product efficiency becomes lower compared to two-ply products
Solution Approach 1:
The patent divides the manufacturing system into multiple independent processing-winding units (main unit and sub units). Each unit can independently process base paper from parent rolls. This segmentation allows parallel processing of multiple base paper layers, enabling the system to handle both long one-ply products and shorter multi-ply products simultaneously, thereby resolving the efficiency loss from extended winding length.
Solution Approach 2:
The patent transitions from a single-processing-line system to a multi-dimensional parallel processing system with multiple processing-winding units operating simultaneously. By adding temporal and spatial dimensions through parallel units, the system can process multiple base paper layers concurrently, converting the sequential bottleneck into parallel throughput and eliminating the efficiency penalty associated with longer one-ply product lengths.
2Device complexity
If only one base-paper feeder is used for one-ply log roll manufacturing, then the manufacturing process is simplified, but the remaining base-paper feeder cannot be used effectively, leading to inefficiency
Solution Approach 1:
The patent designs multiple processing-winding units that can universally handle different base paper configurations. Each unit can process base paper from individual parent rolls or work in coordination with other units. This multi-functionality ensures that all base-paper feeders remain actively utilized regardless of whether one-ply or multi-ply products are being manufactured, eliminating idle feeders and optimizing resource utilization.
Solution Approach 2:
The patent implements a dynamic system where the allocation of parent rolls to processing units can be flexibly adjusted based on production requirements. When manufacturing one-ply products, parent rolls can be distributed across multiple sub units rather than concentrated on one feeder, allowing the system to dynamically optimize feeder utilization and prevent any single feeder from becoming underutilized.
3Adaptability or versatility
If multiple parent rolls are used to feed base paper, then multi-ply log rolls can be manufactured, but the system cannot effectively produce one-ply log rolls without leaving feeders unused
Solution Approach 1:
The patent segments the base paper feed system into multiple independent processing-winding units, each capable of handling parent rolls independently or in coordination. This segmentation allows the system to flexibly allocate parent rolls to different units based on whether one-ply or multi-ply products are being produced, ensuring that all feeders remain productive regardless of product type, thus maintaining both versatility and efficiency.
Data Source
Figure 1(a)~1(b)
Figure 2
AI summary
A log roll can be efficiently manufactured in a log roll manufacturing apparatus capable of manufacturing a multi-ply log roll by using a plurality of parent rolls. When yet-to-be-wound base paper 12 constituted of stacked sheets of first base paper 11a and second base paper 11b fed from first and second parent rolls 10A and 10B is supplied to a main processing-winding unit 50A, if a winder 1 capable of manufacturing a two-ply log roll 62 and including a sub processing-winding unit 50B is to manufacture a one-ply log roll 61 by using the main processing-winding unit 50A, the yet-to-be-wound base paper 12 constituted of the stacked sheets of the first base paper 11a and the second base paper 11b is separated into first separated yet-to-be-wound base paper 12a and second separated yet-to-be-wound base paper 12b by a base-paper separating unit 70. Then, one-ply log rolls 61 are simultaneously manufactured by using the main processing-winding unit 50A supplied with the first separated yet-to-be-wound base paper 12a and the sub processing-winding unit 50B supplied with the second separated yet-to-be-wound base paper 12b.