Paper Folding and Cutting Module for Fast Format Changeovers
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Solution Overview
Problem
Existing paper converting machines are structurally complex, large in size, and require high energy consumption due to the need for multiple rolls and suction systems, limiting versatility and productivity in producing different types of laminar products.
Innovation Solution
A machine with a support frame that supports a feeding, cutting, and folding/interfolding group, where the cutting and folding/interfolding units are mounted on a support body that can be easily displaced between assembled and disassembled positions, allowing quick replacement and adjustment of components, and a displacement group with engagement portions for seamless movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple rolls and suction systems are used for cutting and folding, then the folding and cutting functions are achieved, but the machine size becomes large and energy consumption increases
Solution Approach 1:
The patent combines the cutting roll and folding roll into a single integrated roll that performs both functions. The roll has cutting edges on its surface that simultaneously cut the web and fold it in one operation, eliminating the need for separate cutting rolls and folding rolls. This merging of functions directly reduces the machine size while maintaining the required cutting and folding capabilities.
Solution Approach 2:
The integrated roll is designed to perform multiple functions: it acts as both a cutting tool and a folding tool. By making the roll universal in its functionality, the patent eliminates the need for multiple specialized rolls, thereby reducing the overall machine footprint and component count while achieving the same operational results.
2Reliability
If multiple rolls and suction systems are used for cutting and folding, then the folding and cutting functions are achieved, but energy consumption increases
Solution Approach 1:
The patent combines the cutting roll and folding roll into a single integrated roll that performs both functions. The roll has cutting edges on its surface that simultaneously cut the web and fold it in one operation, eliminating the need for separate cutting rolls and folding rolls. This merging of functions directly reduces the machine size while maintaining the required cutting and folding capabilities.
Solution Approach 2:
The integrated roll is designed to perform multiple functions: it acts as both a cutting tool and a folding tool. By making the roll universal in its functionality, the patent eliminates the need for multiple specialized rolls, thereby reducing the overall machine footprint and component count while achieving the same operational results.
3Stability of the object's composition
If folding rolls with predetermined circumference are used, then the folding operation is stable, but the machine cannot easily produce different panel lengths
Solution Approach 1:
The patent makes the roll circumference adjustable rather than fixed. The integrated roll can be configured with different circumferences depending on the desired panel length, allowing the machine to adapt to different production requirements. This dynamic adjustability enables the same machine to produce various panel lengths while maintaining stable folding operations through proper roll configuration.
Solution Approach 2:
The patent changes the physical parameter of roll circumference to enable different panel lengths. By adjusting the roll circumference parameter, the machine can produce different panel lengths without requiring complete roll replacement. This parameter change approach maintains operational stability while providing versatility in product specification.
4Manufacturing precision
If complete replacement of folding rolls is required to change panel length, then the folding precision is maintained, but the production downtime increases
Solution Approach 1:
The patent makes the roll circumference adjustable rather than fixed. The integrated roll can be configured with different circumferences depending on the desired panel length, allowing the machine to adapt to different production requirements. This dynamic adjustability enables the same machine to produce various panel lengths while maintaining stable folding operations through proper roll configuration.
Solution Approach 2:
The patent changes the physical parameter of roll circumference to enable different panel lengths. By adjusting the roll circumference parameter, the machine can produce different panel lengths without requiring complete roll replacement. This parameter change approach maintains operational stability while providing versatility in product specification.
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
Enables easy and quick replacement of machine components, reduces the overall machine size, and minimizes downtime for maintenance, enhancing versatility and productivity in producing laminar products like napkins and tissues.
Implementation Method 1
a vacuum generation device configured to generate a vacuum to a predetermined degree; a vacuum distribution device configured to selectively and pneumatically connect the vacuum generation device to at least one row of the plurality of rows of suction holes, at predetermined angular positions of the tubular body, in such a way to cause the sheets of paper to be sucked and therefore to be held on the folding rolls
Data Source
AI summary
A machine (1) for producing packages of napkins, tissues, towels, or similar products, comprises a support frame (100) to support a feeding group (10) which feeds a first and a second web of paper (5a, 5b). The support frame (100) supports, furthermore, a cutting group (20) which cuts the first and second webs of paper (5a, 5b) respectively in a first and a second plurality of sheets (6) of predetermined length, and a folding or interfolding group (30) which folds or interfolds the sheets of paper (6) at a folding or interfolding zone, (35) in such a way to obtain a stack (150) of folded or interfolded sheets, according to a predetermined folding or interfolding configuration. The cutting group (20) and the folding or interfolding group (30) are mounted on the same support body (110) to move between an assembled position in which is supported by the support frame (100), and a disassembled position, in which is not supported by the support frame (100). A displacement group (50) is, furthermore, provided to displace the support body (110) between the assembled position and the disassembled position. The displacement group (50) and the support body (110) are provided with respective engagement portions (58,118) to engage with each other in such a way to allow the displacement group (50) to displace the support body (110) between the assembled position and the disassembled position.