Log Saw Unit Selective Feeding Channels
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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 machine downtime and increased costs due to the need for additional deviator belt devices, which are bulky and not optimal in terms of cost and layout.
Innovation Solution
A method that uses 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 directed to a single operational packaging machine, 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 removes the deviator belt device from the system entirely. Instead of adding a separate sorting mechanism, it integrates the selection function directly into the log saw unit by controlling which feeding channels are active. This extracts the unnecessary intermediate device while maintaining the selective feeding capability through the existing channel structure.
Solution Approach 2:
The log saw unit's feeding channels are made multi-functional. They not only perform their primary function of transporting logs to the cutting device but also serve as the selection mechanism for directing rolls to different packaging machines. By controlling which channels are active, the system achieves both cutting and selective routing functions without additional devices.
2Reliability
If deviator belt devices are added to selectively sort rolls, then packaging machine availability is improved, but installation cost and space requirements increase
Solution Approach 1:
The patent eliminates the deviator belt device and its associated space requirements. The selective feeding function is achieved by simply controlling which of the existing feeding channels are operational, removing the need for additional sorting equipment and the space it would occupy in the plant layout.
Solution Approach 2:
The patent merges the selective routing function with the existing log feeding channels. The same channels that transport logs to the cutting device are used to direct the resulting rolls to different packaging machines. This consolidation eliminates the need for separate deviator belts and reduces overall plant layout space requirements.
3Device complexity
If all feeding channels are stopped when one packaging machine stops, then system simplicity is maintained, but productivity is reduced
Solution Approach 1:
The patent segments the feeding channels into independent controllable units. Each feeding channel can be stopped or continued independently based on the status of specific packaging machines. This segmentation allows the system to maintain simplicity in control logic while achieving selective feeding to different machines, thereby preserving productivity when one machine is down.
4Ease of manufacture
If conveyor length is minimized to reduce costs, then installation cost is reduced, but ability to handle machine downtime is worsened
Solution Approach 1:
The patent prepares the system in advance by having multiple feeding channels ready and the log saw unit capable of selective operation. When a packaging machine goes down, the system can immediately redirect rolls from other channels without requiring long conveyors to buffer the rolls. This preliminary preparation of the feeding system eliminates the need for extended conveyor lengths while maintaining downtime handling capability.
Data Source
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.