Reel Joining Apparatus With Pulling Bars For Tissue Production
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Solution Overview
Problem
Existing unwinding apparatuses for large-diameter reels used in tissue paper production face interruptions and delays due to paper winding defects, which require manual intervention to remove defective sections and rejoin the paper ribbon, leading to inefficiencies and downtime in the processing line.
Innovation Solution
An apparatus with dual unwinders and a joining device featuring pulling bars and cutting mechanisms allows for the continuous unwinding and joining of new reels with depleting reels, enabling automated operation and defect management without interrupting the process, by synchronizing the pulling speed of the pulling bars with the unwinding speed of the reels to maintain continuous operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual intervention is used to remove defective sections and rejoin the paper ribbon, then defects can be eliminated, but processing interruptions and downtime occur
Solution Approach 1:
The system uses sensors to automatically detect defects in the paper ribbon and triggers the cutting and joining mechanisms without human intervention. The defective sections are automatically removed and the plies are automatically rejoined, allowing the system to service itself and maintain continuous operation while ensuring quality standards are met.
2Loss of time
If a new reel is loaded in stand-by position when the previous reel is close to depletion, then replacement time is reduced, but the unwinder dimensions must accommodate large reels
Solution Approach 1:
The system loads the new reel in the stand-by position in advance, before the current reel is completely depleted. This preliminary action allows the replacement to occur quickly by simply switching from one reel to the other, minimizing downtime. The stand-by position is designed to accommodate reel dimensions while enabling rapid replacement without requiring the unwinder to be excessively large.
3Extent of automation
If automated joining is implemented, then manual labor is reduced, but system complexity increases
Solution Approach 1:
The system introduces an intermediary joining mechanism that automatically connects the plies from two different reels. This intermediary device mediates between the reels and the processing line, handling the complex joining operation automatically. While it does increase device complexity, it enables full automation of the joining process, eliminating manual labor and ensuring consistent, reliable connections.
4Productivity
If the pulling speed is synchronized with the unwinding speed, then continuous operation is maintained, but control precision requirements increase
Solution Approach 1:
The system employs feedback control mechanisms that continuously monitor the unwinding speed of the reels and adjust the pulling speed of the joining mechanism accordingly. Sensors detect speed variations and provide feedback to the control system, which makes real-time adjustments to maintain precise synchronization. This feedback loop enables continuous operation while managing the precision requirements through active control rather than passive mechanical coupling.
Data Source
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AI summary
The present invention relates to an apparatus and method for unwinding reels and for joining a ply between two reels. The apparatus (1) comprises a first unwinder (2) adapted to unwind a first reel (21) and a second unwinder (3) adapted to unwind a second reel (31). The apparatus (1) further comprises a joining device (4) adapted to join a first ply (22) belonging to said first reel (21) with a second ply (32) belonging to said second reel (31), The joining device (4) comprises a pair of pulling bars (40, 41), where a first pulling bar (40) is able to pull a flap of said first ply (22) along a joining path with said second ply (32), while a second pulling bar (41) is adapted to pull a flap of said second ply (32) along a joining path with said first ply (22). The joining device (4) further comprises joining means (5) configured to join, in a joining point along said joining path, said flap of said first ply (22) with said second ply (32) or said flap of said second ply (32) with said first ply (22). The joining device (4) further comprises first cutting means (6) configured to cut said first ply (22) or said second ply (32) upstream of said joining point where the joint is performed between said first ply (22) and said second ply (32) and second cutting means (7) configured to cut said flap of said first ply (22) or said flap of said second ply (32) downstream of said joining point.