Pendulum Conveyor for Diaper Blank Folding
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Solution Overview
Problem
Existing methods for folding nappy/diaper blanks at high production speeds face difficulties in transferring and releasing the leading portion from one roller to another due to counter-rotating rollers, leading to dragging forces that cause imperfect matches and plastic deformations, affecting subsequent welding or sealing steps.
Innovation Solution
A machine with a pendulum conveyor system that transfers the leading portion from one roller to another, using suction means and restraining elements to manage the blank's movement, ensuring smooth transfer and minimizing dragging forces by coordinating the motion of rollers and pendulum conveyor to maintain continuous and precise folding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If counter-rotating rollers are used to transfer the leading portion from one roller to another, then the folding process can be completed, but dragging forces are generated causing plastic deformations and imperfect matches
Solution Approach 1:
A transfer belt is introduced as an intermediary element between the first and second rollers. The transfer belt moves in the same direction as the leading portion's travel, providing a non-dragging transfer surface. This mediator eliminates the harmful counter-rotating roller interaction while still enabling the transfer function to be completed.
Solution Approach 2:
The direct mechanical interaction between counter-rotating rollers is replaced with a belt-based transfer system. Instead of using roller friction and contact forces that cause dragging, the patent employs a belt that conveys the blank smoothly from one roller to the other, substituting a mechanical contact system with a more gentle conveyance mechanism.
2Productivity
If counter-rotating rollers are used for continuous rotation, then the folding process can proceed continuously, but suction means deactivation at transfer moment creates transfer difficulties
Solution Approach 1:
The transfer belt serves as a continuous intermediary that bridges the suction deactivation gap. While suction is deactivated on the rollers, the belt maintains continuous contact with the blank and provides the necessary transfer function, ensuring seamless operation without interruption.
Solution Approach 2:
The transfer belt ensures continuous useful action by maintaining constant contact with the blank throughout the transfer process. Unlike the roller system where suction must be deactivated, the belt system allows continuous conveyance without interruption, preserving the continuity of the folding operation.
3Force
If dragging and pulling forces are applied during folding, then the blank can be moved through the folding station, but plastic deformations occur in the blank portion
Solution Approach 1:
The harsh mechanical dragging forces of counter-rotating rollers are replaced with the gentle conveyance of a transfer belt. The belt moves the blank through the folding station without applying harmful tensile or compressive forces, thereby preventing plastic deformations while still achieving the necessary movement.
Solution Approach 2:
The transfer belt acts as a cushioning element that protects the blank from harmful forces during transfer. By providing a compliant, non-dragging contact surface, the belt cushions the blank against the damaging effects of forceful manipulation, preventing deformation before it can occur.
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 solution enables efficient and precise folding of nappy/diaper blanks, reducing the risk of deformation and ensuring accurate alignment even at high production speeds, resulting in improved matching and reduced damage during the folding process.
Implementation Method 1
using suction means and restraining elements to manage the blank's movement
Data Source
Figure 1
Figure 2
Figure 3~7
AI summary
Blanks used in the manufacture of nappies/diapers are folded on a machine comprising a first aspirating roller (5) by which single blanks (2) are advanced in succession toward a second aspirating roller (6) rotating counter and substantially tangential to the first roller (5) at a folding station (T). The first roller (5) is equipped with movable restraining elements (8) designed to engage an intermediate part of each advancing blank (2), so that a leading half of the blank remains free to be taken up by a transfer mechanism (11) operating between the first and second rollers (5, 6) in an area upstream of the folding station (T), and transferred from the first roller (5) to the second roller (6); as the two rollers (5, 6) rotate, the trailing half of the blank (2) retained on the first roller (5) by the restraining elements (8) is drawn closer to the leading half, whereupon the two halves converge gradually until flattened one against the other on passing through the folding station (T), which coincides with the point of tangency between the two rollers (5, 6), and the fold in the blank (2) is complete. The transfer mechanism (11) swings pendulum fashion, moving in sympathy with the first roller (5) when the leading half of the blank (2) is taken up and detached from this roller and in sympathy with the second roller (6) once the leading half of the blank has been released to this same second roller.