Nose Wire Splicing via Accumulation Buffer
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Solution Overview
Problem
Current facemask production lines are unable to meet high demand during pandemics due to limitations in technology and equipment, producing only about 100 masks per minute, whereas an estimated 1,500 masks per minute are needed, and there is a need for a method to splice nose wires efficiently in mass production without stopping or slowing the production line.
Innovation Solution
A method and system for splicing a reserve nose wire into a running nose wire in a facemask production line by moving the supply roll to an intermediate location, forming an accumulation of the running wire, and then splicing the reserve wire into it without stopping the production line, allowing continuous operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the production line operates continuously at high speed, then productivity is improved, but the ability to splice nose wires deteriorates (requires stoppage or slowdown)
Solution Approach 1:
The patent applies preliminary action by moving the supply roll to an intermediate location and forming an accumulation of running wire before the splice operation. This preparation allows the splice to be performed without stopping the production line, as the accumulation provides a buffer that enables the splice while maintaining continuous feed to the masks.
Solution Approach 2:
The patent uses an intermediate location as a mediator between the supply roll and the production line. By positioning the supply roll at an intermediate location and creating an accumulation zone, the system mediates the conflict between continuous high-speed production and the need to perform splice operations without direct interruption.
2Ease of manufacture
If the production line is stopped or slowed for splicing, then nose wire splicing becomes easier, but productivity deteriorates
Solution Approach 1:
The patent implements continuity of useful action by ensuring that the production line never stops or slows down during the splice operation. The accumulation of running wire formed at the intermediate location provides a continuous supply buffer, allowing the splice to occur while the line maintains its high-speed operation throughout the process.
3Productivity
If mass production at high throughput is implemented, then productivity is improved, but the complexity of splicing operations increases
Solution Approach 1:
The patent applies segmentation by dividing the splicing system into distinct functional zones: the supply roll location, the intermediate location with accumulation zone, and the splice point. This segmentation allows each zone to perform its specific function independently, managing the complexity of high-speed splicing through spatial division of operations.
Data Source
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AI summary
A method and associated system are provided for splicing a reserve nose wire (102) to a running nose wire (104) in a facemask production line (106), wherein the running nose wire (104) is supplied continuously from a supply roll (130). Prior to depletion of the running nose wire (104), the supply roll (130) is moved from an operating location to an intermediate location that is further from the production line while continuing to supply the running nose wire (104) from the supply roll (130). The supply roll (130) is then moved from the intermediate location back towards the production line while decelerating the supply roll (130) to a stop, thereby creating an accumulation (152) of the running wire (104) functionally between the supply roll (130) and the production line (106). With the supply roll (130) at a stop, the running nose wire (104) is continuously supplied from the accumulation (152) and a leading end (132) of a reserve roll (128) of nose wire (102) is spliced to the running nose wire (104) at a location upstream of the accumulation (152) where the running nose wire (104) is at a standstill. The running nose wire (104) is then cut at a location upstream of the splice such that the reserve nose wire (102) and reserve roll (128) become a new running nose wire and new supply roll in the production line.