Rewinder Machine Optical Diameter Control for Paper Logs
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The production of paper logs faces challenges in maintaining consistent diameter due to surface wear of winding rollers and debris, which affects the thickness of the paper web wound onto the cores, leading to inconsistent log formation.
Innovation Solution
A control system that uses an optical vision system with edge-detection algorithms to measure the diameter of the logs and automatically adjust the paper web thickness by controlling the speed of the rollers and tensioning devices, ensuring consistent log formation by comparing actual diameters with predetermined values.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If surface wear of winding rollers and debris are present, then the winding process continues, but the diameter of the logs becomes inconsistent
Solution Approach 1:
The patent implements a feedback control system where the actual diameter of the log is measured and compared with the target diameter. The difference (error signal) is fed back to the control unit, which automatically adjusts the speed of the winding rollers to compensate for surface wear and debris, thereby maintaining consistent log diameter throughout the continuous winding operation.
Solution Approach 2:
The patent replaces manual monitoring and adjustment with an automated control system that uses optical measurement devices and electronic control units. This substitution of mechanical/manual processes with optical and electronic systems enables continuous automatic adjustment of roller speed to maintain diameter consistency without interrupting production.
2Device complexity
If manual monitoring of log diameter is used, then the system is simple, but the control quality depends on operator experience
Solution Approach 1:
The control system is designed to be self-regulating, automatically measuring the log diameter and adjusting the roller speed without requiring operator intervention. The system monitors itself and corrects its own deviations, eliminating the variability introduced by human operators and ensuring consistent control quality throughout the day.
Solution Approach 2:
The patent replaces manual visual inspection and operator judgment with automated optical measurement devices and electronic control systems. This substitution eliminates the dependency on operator experience while maintaining system simplicity, as the automated system requires minimal configuration but provides reliable, consistent control.
3Reliability
If the paper thickness is increased to compensate for roller wear, then the log diameter increases, but the quality of the paper log decreases
Solution Approach 1:
The patent employs dynamic adjustment of the paper web thickness during the winding process. Instead of using a fixed thickness, the system continuously varies the thickness based on real-time diameter measurements and the current state of the winding rollers, allowing optimal compensation that maintains both diameter stability and paper log quality.
Solution Approach 2:
The control system dynamically changes multiple parameters including roller speed and paper web thickness in a coordinated manner. By adjusting these parameters together rather than independently, the system achieves diameter compensation while minimizing negative impacts on paper log quality, such as excessive tension or uneven winding.
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 system maintains constant rewinder control over time, independent of operator experience, and allows for the use of commercially available optical devices, providing low-cost solutions to ensure consistent paper log diameter and quality.
Implementation Method 1
an optical vision system with edge-detection algorithms to measure the diameter of the logs
Data Source
AI summary
Rewinder for making paper logs of paper material including a detection system with optical means adapted to detect, in a succession of predetermined detection times, a succession of diameters assumed in such times by a log being formed in a winding station and a programmable electronic unit which compares the diameters measured by the optical means with a succession of corresponding preset diameters and to calculate a sequence of differences. The processing unit receives a signal relating to the value of the actual diameter of the completed log and determines a parameter related to the trend over time of the differences. Elements for adjusting the thickness of the paper web automatically adjust said thickness if the parameter is between predetermined values.