Pivoting Hub Roll Loading Without Heavy Mandrels
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Solution Overview
Problem
Conventional roll-feeding systems face challenges with heavy mandrels that are difficult to install and prone to breaking, requiring manual lifting and limiting the use of lifting devices like cranes or forklifts due to restricted access, leading to inefficiencies and delays.
Innovation Solution
A system utilizing pivotably mounted hubs that transition between operational and deflected positions to support and handle rolls of web material without the need for an axle or mandrel within the tubular core, allowing for easier loading and unloading by pivoting up and away from the roll, enabling secure seating within the core.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a heavy mandrel is used to support the roll of web material, then the roll can be supported and handled, but the mandrel is difficult to install and prone to breaking
Solution Approach 1:
The patent removes the mandrel from the system entirely and replaces it with a tubular core that is an integral part of the roll structure. The hubs engage directly with the tubular core through interference fit, eliminating the separate mandrel component that caused installation difficulties and breakage risks.
Solution Approach 2:
The hubs are designed to nest within the tubular core structure, with the hub faces engaging the inner surface of the tubular core. This nested arrangement provides secure support while allowing for easier installation and removal compared to traditional mandrels.
2Weight of moving object
If conventional lifting devices are used to lift the roll of web material, then the heavy roll can be lifted, but restricted access to the mounting position limits the use of these devices
Solution Approach 1:
The hubs are made pivotable rather than fixed, allowing them to move between an operational position (engaging the tubular core) and a retracted position (clear of the roll). This dynamic positioning enables lifting devices to approach from various angles and makes the loading/unloading process more flexible and accessible.
3Ease of operation
If manual lifting is used due to restricted access, then lifting can be performed, but it causes delay and reduces overall efficiency
Solution Approach 1:
The pivotable hubs enable automated or semi-automated loading mechanisms to position and secure rolls efficiently. The hubs can pivot into position to engage the tubular core and pivot out of the way for quick unloading, significantly improving loading efficiency compared to manual operations.
Solution Approach 2:
The hub design allows the roll itself to facilitate the loading process. When the roll is positioned, the hubs naturally pivot into engagement with the tubular core through the roll's weight and positioning, reducing the need for complex manual manipulation and improving overall loading speed.
4Reliability
If a fixed hub position is used to support the roll, then the roll is securely supported, but the hub cannot be easily removed or repositioned
Solution Approach 1:
The hubs are designed with pivotable mounting that allows them to transition between a secured operational position (where they firmly support the roll) and a retracted position (where they can be easily removed or repositioned). This dynamic capability maintains support stability while enabling easy maintenance and reconfiguration.
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.