Log Saw Unit Selective Roll Feeding Control
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Solution Overview
Problem
The existing methods for selectively feeding rolls of paper from a log saw unit to packaging machines are inefficient, leading to unnecessary machine downtime and increased costs due to the need for additional deviator belt devices, which complicate the plant layout and are not optimal in terms of cost and bulk.
Innovation Solution
A method that utilizes a log saw unit with independently controlled feeding channels and cradles, equipped with servomotors and photocells, to selectively stop and restart the feeding process based on packaging machine status, allowing rolls to be redirected to operational packaging machines, thereby minimizing downtime and conveyor length.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If deviator belt devices are added to selectively sort rolls, then packaging machine availability is improved, but device complexity and plant layout bulk increase
Solution Approach 1:
The patent extracts the selective routing function from a separate deviator belt device and integrates it directly into the log saw unit's conveyor system. The conveyor belts themselves are configured to selectively feed rolls to different packaging machines based on their operational status, eliminating the need for external deviator devices while maintaining the roll redirection capability.
Solution Approach 2:
The conveyor belts in the log saw unit perform multiple functions: they transport rolls from the cutting device and simultaneously provide selective routing to different packaging machines. This multi-functionality eliminates the need for dedicated deviator belts, reducing overall device complexity while maintaining packaging machine availability.
2Reliability
If deviator belt devices are added to selectively sort rolls, then packaging machine availability is improved, but cost and bulk increase
Solution Approach 1:
The patent removes the need for separate deviator belt devices by integrating the selective routing function into the existing conveyor belts of the log saw unit. This extraction of the routing function from a separate device reduces material costs, manufacturing complexity, and installation expenses while maintaining the ability to redirect rolls to available packaging machines.
Solution Approach 2:
By making the conveyor belts multi-functional (both transport and selective routing), the patent eliminates the need for additional deviator belt devices, thereby reducing overall system cost while achieving the same reliability improvement in packaging machine availability.
3Productivity
If the log saw unit stops when one packaging machine stops, then feeding simplicity is maintained, but productivity is reduced
Solution Approach 1:
The patent implements a dynamic control system that automatically adjusts the log saw unit's feeding operation based on the real-time status of packaging machines. When a packaging machine stops, the control system dynamically redirects rolls to operational machines through the conveyor belts, allowing the log saw unit to continue production without complete shutdown and thereby maintaining higher productivity.
Solution Approach 2:
The control system receives feedback from packaging machines regarding their operational status and automatically adjusts the feeding operation accordingly. This feedback mechanism enables the log saw unit to respond to machine stoppages by redirecting rolls to available packaging machines, preventing unnecessary shutdowns and maintaining productivity without requiring complex manual intervention.
Data Source
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AI summary
A method for selectively feeding rolls of paper coming out of a log saw unit (10), wherein the log saw unit (10) comprises (n) feeding channels (12) for feeding logs (11) towards a cutting device (13) provided at the outlet with (n) unloading belts (14) in a number equal to the feeding channels (12), comprises a step of generating a stop signal relating to a portion of a packaging unit downstream of the log saw unit (10) further to the detection of accumulation of rolls (11') and/or of stopping of a packaging machine, as well as a step of attributing said stop signal to a feeding channel/sub-group of feeding channels (12) operatively associated with the portion of the packaging unit, called "feeding channels/sub-groups of feeding channels (12) subject to stopping", wherein the method - upon receipt of the stop signal - comprises at least the steps of: - ending the cutting of the log (11) in progress on all of the (n) feeding channels (12) of the log saw unit (10), - selectively stopping the forward movement of a new log (11) towards the cutting device (13) just in the feeding channels/sub-groups of feeding channels (12) subject to stopping through the stopping of the forward movement of the carriers (15) of the carrier device (16) of the feeding channels/sub-groups of feeding channels (12) subject to stopping, - proceeding without interruption in the operative feeding channels (12), namely those not subject to the stop signal, with the cutting of the logs (11) in succession.