Optical Roll Diameter Sensing for Low-Waste Stock Splicing
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Solution Overview
Problem
Existing systems for unwinding rolled stock suffer from significant waste due to variable marking placement by manufacturers, leading to inefficient splicing and manual intervention, resulting in up to 3% of rolled medium remaining unusable on the core.
Innovation Solution
A sensor assembly that detects the quantity of rolled stock on the core, communicating with a splice actuation system to initiate a seamless transition to a new roll, reducing waste by ensuring minimal stock remains after splicing, utilizing machine vision to accurately determine the low stock threshold.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a physically placed marking is used to indicate low roll diameter, then the system can detect when to splice, but the marking placement variability causes significant medium waste on the core
Solution Approach 1:
The patent replaces the mechanical/physical marking system with an optical sensing system. Instead of relying on physically placed markings that vary in position, the system uses an optical sensor to detect the core diameter by measuring the reflection or transmission of light through the rolled medium, enabling precise detection without waste-causing variability
Solution Approach 2:
The patent creates an optical copy or representation of the physical state by using light to measure the core diameter. The sensor captures optical information about the roll's current state, converting physical dimensions into detectable optical signals that can be processed to determine when splicing is needed
2Reliability
If manufacturers position the marking with a safe amount of medium on the core, then manual splicing is avoided, but a substantial amount of medium remains unused on the core as waste
Solution Approach 1:
The patent implements a feedback control system where the optical sensor continuously monitors the core diameter and provides real-time information about the remaining medium. This feedback enables the system to automatically initiate splicing at the optimal moment, eliminating the need for conservative 'safe amount' positioning and preventing waste while maintaining reliability
Solution Approach 2:
The system enables self-service by allowing the unwinding system to automatically detect and respond to low medium levels without manufacturer intervention. The optical sensing system and automated splicing mechanism work together to manage the medium depletion process, eliminating waste caused by conservative marking placement strategies
3Productivity
If manual splicing is performed when the roll runs out of medium, then the system can continue operation, but labor and time are consumed resulting in system downtime
Solution Approach 1:
The patent applies preliminary action by detecting the core diameter and initiating the splicing process before the medium is completely depleted. The optical sensor continuously monitors the roll state and triggers splicing in advance, allowing the system to transition between rolls without interruption or downtime
Solution Approach 2:
The patent ensures continuity of useful action by maintaining an uninterrupted supply of medium through automated splicing. The optical detection system enables seamless transition between rolls, eliminating downtime and ensuring continuous operation without breaks in the productive process
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system effectively reduces rolled stock waste by ensuring almost complete utilization of the stock, with only a few impressions remaining after splicing, thereby minimizing labor-intensive manual splicing and system downtime.
Implementation Method 1
a sensor configured to detect a first roll of stock unwinding from a core
Data Source
AI summary
A sensor assembly configured to detect rolled stock on a core includes a sensor configured to detect a first roll of stock unwinding from a core, the stock unwinding from the core of the first roll is supplied as a web of stock, wherein in response to the sensor detecting a first detection configuration, the sensor takes no action and continues to detect the first roll, and wherein in response to the sensor detecting a second detection configuration, the sensor provides a command to a splice assembly to transition to a second roll of stock to replace the first roll of stock.