Pouch Roll Height Alignment for Automated Chuck Replacement

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Solution Overview

Problem

The existing pouch roll replacement systems face challenges in adjusting the chucking height of replacement pouch rolls according to their varying diameters, leading to potential safety hazards and increased workload due to manual adjustments, especially when transporting heavy rolls.

Innovation Solution

A system comprising a transport part, a replacement chucking part, an unwinder chucking part, a measuring part, and a control part that adjusts the central axis height of the replacement pouch roll based on measured diameter and chucking height differences to match the chucking heights of the chucking parts, ensuring safe and automated replacement and unwinding processes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If manual adjustment of pouch roll height is performed, then the pouch roll can be positioned to match chucking height, but the workload increases and safety risks arise due to heavy weight (200 kg or more)

Engineering Contradiction:

Improveease of pouch roll positioningVSAvoidsafety risk from heavy roll

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The system enables self-service by automatically measuring the pouch roll diameter, calculating the required height adjustment, and actuating the height adjustment unit without human intervention. The control unit orchestrates the entire process from measurement to positioning, eliminating manual handling of heavy rolls.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

Manual mechanical adjustment is replaced with an automated system comprising a measuring unit for diameter detection, a control unit for calculation, and a height adjustment unit with actuator for mechanical positioning. This substitution eliminates the need for workers to manually position heavy pouch rolls.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Ease of manufacture

If equipment shutdown occurs for pouch roll replacement, then the replacement can be performed, but productivity decreases due to frequent stoppages

Engineering Contradiction:

Improveease of pouch roll replacementVSAvoidproduction efficiency

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The standby pouch roll is pre-positioned on the standby chucking unit with automatic height adjustment before replacement is needed. When replacement is required, the system already has the new roll ready at the correct height, enabling immediate swap without equipment shutdown or manual preparation.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The standby chucking unit serves as an intermediary, holding the replacement pouch roll ready at the correct height. This intermediate positioning allows the main unwinder to be replaced without shutdown, as the standby unit can immediately take over when the replacement is complete.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Adaptability or versatility

If pouch roll diameter varies, then different pouch rolls can be used, but the chucking height becomes inconsistent requiring manual adjustment

Engineering Contradiction:

Improveadaptability to different roll diametersVSAvoidease of height adjustment

Core Design Contradiction:

Adaptability or versatilityVSEase of operation

Solution Approach 1:

The measuring unit provides feedback on the actual pouch roll diameter, which the control unit uses to calculate the precise height adjustment needed. This closed-loop feedback system ensures that regardless of diameter variations, the pouch roll is automatically positioned at the correct chucking height.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The system dynamically changes the height parameter of the pouch roll positioning based on measured diameter variations. The control unit adjusts the height adjustment unit's position according to the calculated difference between the actual and target chucking heights, accommodating different roll diameters automatically.

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS20250011119A1Pouch Roll Replacement System

Publication Date: 2025.01.09 LG ENERGY SOLUTION LTD

AI summary

A pouch roll replacement system comprises a transport part, a replacement chucking part, an unwinder chucking part, a measuring part, and a control part. The transport part transports a replacement pouch roll and is capable of adjusting the central axis height of the replacement pouch roll The replacement chucking part is provided to chuck the replacement pouch roll transported through the transport part and has a predetermined chucking height The unwinder chucking part accommodates a traveling pouch roll and the measuring part measures the distance to the replacement pouch roll seated on the transport part before transporting the replacement pouch roll to the replacement chucking part. The control part controls the transport part so that the central axis height of the replacement pouch roll seated on the transport part is adjusted based on the measurement information of the measuring part and the chucking height of the replacement chucking part.