Pivoting Hub Roll Loader to Eliminate Mandrel Handling
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Solution Overview
Problem
Conventional roll-feeding systems require precise placement of heavy mandrels, which are prone to breaking and difficult to install, and often restrict the use of lifting devices like cranes or forklifts due to restricted access, leading to inefficiencies and manual handling challenges.
Innovation Solution
A system utilizing pivotably mounted hubs that deflect to allow easy loading and unloading of rolls without the need for a mandrel, with hubs transitioning between operational and deflected positions to support the roll's weight and facilitate handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional mandrel system is used to support the roll of web material, then the roll can be supported and handled, but the mandrel is heavy (30-50 pounds), difficult to install, and prone to breaking
Solution Approach 1:
The invention extracts and eliminates the mandrel component entirely from the system. Instead of using a separate mandrel that needs to be inserted into the hollow core, the hub itself becomes the support structure that directly engages with the roll ends, removing the problematic intermediate component
Solution Approach 2:
The hub serves multiple functions: it supports the roll weight, provides a mounting surface for the brake mechanism, and directly engages with the roll ends without requiring a separate mandrel. This multi-functional design consolidates several components into one
2Reliability
If precise placement of heavy mandrels is required, then the roll can be properly supported, but the process is time-consuming and reduces overall efficiency
Solution Approach 1:
The hub is designed with dynamic capability to pivot between positions. The pivot mechanism allows the hub to move from a loading position where it can be easily approached from above, to an operational position where it securely supports the roll, enabling both efficient loading and stable support
Solution Approach 2:
The hub is pre-positioned in a deflected loading position above the roll before the roll is placed. This preliminary positioning allows the roll to be lowered into place without requiring precise manual alignment, as the hub is already in the correct position to receive it
3Ease of operation
If restricted access to the mounting position is present, then conventional lifting devices like cranes or forklifts cannot be used, but manual lifting becomes difficult and delays the process
Solution Approach 1:
Instead of bringing the roll up to a fixed hub position (which would require access from below), the hub is inverted to a deflected position above the roll. This allows the roll to be lifted vertically in the clear space below the mounting position, avoiding the need for lateral access to restricted areas
Solution Approach 2:
The hub pivot mechanism adds a rotational dimension to the loading process. By pivoting the hub from a vertical loading position to a horizontal operational position, the system creates three-dimensional movement space that bypasses two-dimensional access restrictions
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
This solution simplifies the handling and loading process by eliminating the need for mandrel placement, reducing manual effort, and enabling efficient use of lifting devices, thereby enhancing operational efficiency and safety.
Implementation Method 1
Each of the hubs is pivotably supported on a pivot mechanism for pivoting movement between an operational position on a horizontal rotational axis and a deflected position in which the hub face of each of the hubs is deflected in an arcuate direction away from the horizontal rotational axis
Implementation Method 2
The pair of hubs is transitioned from the operational position to the deflected position by the roll of web material when the roll of web material is lifted from beneath the horizontal rotational axis of the pair of hubs. Subsequent lowering of the roll of web material allows the pair of hubs to transition from the deflected position to the operational position
Data Source
AI summary
A web roll handling and loading system and methods employ hubs positioned on opposing sides of a roll of web material wound on a hollow tubular core. Hub faces have an annular shape configured to be seated in respective ends of the hollow tubular core. The hubs are pivotably supported for pivoting between an operational position and a deflected position. The roll of web material is loaded on the hubs by lifting it from beneath the hubs to deflect the hub faces arcuately upward, then lowering the roll to allow the hub faces to pivot downward and become seated in the ends of the hollow tubular core. Alternatively, the roll is loaded into a pick-up tool by lowering the pick-up tool downward to the roll so the hubs deflect arcuately upward, then raising the tool so the hubs pivot downward and become seated in the hollow tubular core.