Paper Rewinder Continuous Reel Change via Dual Cradle Segmentation
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Solution Overview
Problem
Conventional paper mill rewinders suffer from noncontinuous operation, leading to production losses, high power consumption, and reel damage due to stop-start cycles, reduced productivity, and out-of-round reels during the winding process.
Innovation Solution
A paper mill rewinder with a secondary pre-forming cradle and transfer mechanism allows continuous reel change outside the main forming cradle, using motorized arms and gripping jaws to support and guide the winding rod, ensuring constant tension and preventing reel damage, with air or water nozzles aiding in strip tearing and winding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional start-stop rewinders are used, then reel formation can be completed, but production losses occur and power consumption increases due to cyclic start-stop operation
Solution Approach 1:
The patent divides the reel formation process into two separate cradles: a main forming cradle for completing reel formation and a secondary pre-forming cradle for preparing reels. This segmentation allows continuous operation while reels are being formed in one cradle, another reel can be prepared in the secondary cradle, eliminating the need to stop the machine for reel changes.
Solution Approach 2:
The secondary pre-forming cradle performs preliminary actions by forming reels in advance before they are needed in the main forming cradle. This preliminary preparation ensures that winding rods are ready and reels are pre-formed, allowing the main process to continue without interruption.
2Productivity
If non-stop reel change is implemented using the same forming cradle, then machine stops are avoided, but winding speed must be reduced and productivity decreases
Solution Approach 1:
By separating reel formation into two independent cradles operating simultaneously, the system eliminates the time loss associated with reel changes. While one cradle completes a reel, the other prepares the next one, maintaining constant operating speed without interruptions.
Solution Approach 2:
The dual cradle system ensures continuous useful action by having both cradles operational at the same time. The main forming cradle continuously forms reels while the secondary cradle continuously prepares replacement reels, eliminating idle time and maintaining constant production flow.
3Manufacturing precision
If reels are formed without support during pre-forming, then device complexity is reduced, but reels become out of round due to weight resting on rollers
Solution Approach 1:
The patent introduces a dedicated support structure in the secondary pre-forming cradle that independently supports winding rods during reel preparation. This segmented support system maintains reel roundness by preventing the weight of formed reels from resting on the rollers, while keeping the main forming cradle structure relatively simple.
4Object-affected harmful factors
If formed reels are not guided during removal, then device complexity is reduced, but paper damage occurs due to pressures and frictions on delicate material
Solution Approach 1:
The patent introduces guide arms as intermediary elements that gently guide formed reels during removal from the main forming cradle. These guide arms prevent direct contact between the reel and potentially damaging surfaces, reducing pressures and frictions on the delicate paper material while adding minimal complexity to the system.
Data Source
Figure 1
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AI summary
The invention pertains to the field of industrial machinery for converting paper and/or for processing strip materials, and relates to a paper mill rewinder for forming reels of paper strip material, in particular, but not exclusively, tissue paper, of conventional or structured type, non-woven, TAD (Through Air Drying), or other similar materials characterized by having a very light weight and low density, with continuous, or non-stop, reel change device. Said rewinder (1) comprises: - a supporting frame (3); - feed means (4) for a winding rod (A); - a main forming cradle (C1) for a reel (B) around said winding rod (A), comprising a first (5) and a second (6) winding roller; - means for unloading (7) said reel (B) once formed; - a control unit, - a secondary pre-forming cradle (C2) for said reel (B), comprising a third winder roller (8) and lateral supporting means for said reel (B); - means for transferring said reel (B) from said secondary pre- forming cradle (C2) to said main forming cradle (C1), where said transfer takes place without interruption to the winding, of the strip (N) onto said rod (A).