Rewinding Machine Four-Roller Winding Dynamics
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Solution Overview
Problem
In paper rewinding machines, the lack of available space and the shape of auxiliary components hinder the implementation of existing solutions for stabilizing logs during winding, and there is a need to reduce glue usage, particularly for the 'flap gluing' phase.
Innovation Solution
A rewinding machine with a mechanism using four winding rollers (R1, R2, R3, R4) where the fourth roller (R4) is positioned to assist in the final winding phase, eliminating the need for two separate nips and reducing glue consumption by acting as a press roller for flap gluing, while maintaining log stability and containment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If two separate groups of three winding rollers are used in initial and final winding phases, then log stability is improved, but device complexity and space requirements increase
Solution Approach 1:
The patent employs a dynamic winding system where the number of active winding rollers changes during the winding process. Initially, three rollers (R1, R2, R3) are active, and in the final phase, a fourth roller (R4) is introduced to complete the winding. This dynamic adjustment allows the system to maintain log stability without requiring two separate fixed groups of rollers, thereby reducing device complexity.
Solution Approach 2:
The winding process is segmented into two phases: an initial winding phase using three rollers (R1, R2, R3) and a final winding phase using four rollers (R1, R2, R3, R4). This segmentation allows the system to achieve log stability in the final phase without needing a completely separate second group of rollers, thus reducing overall device complexity.
2Stability of the object's composition
If traditional winding mechanisms are used, then log containment is achieved, but space requirements increase
Solution Approach 1:
The patent uses a dynamic roller configuration where rollers can be positioned and removed as needed. The fourth roller (R4) is introduced only when necessary for final winding, allowing the system to maintain log containment with minimal space requirements throughout the entire process.
Solution Approach 2:
The winding rollers serve multiple functions: they provide log containment during winding, act as press rollers for flap gluing, and can be repositioned for different phases of the winding process. This multi-functionality reduces the need for separate dedicated components, thereby reducing space requirements.
3Strength
If sufficient glue is applied for flap gluing, then bonding strength is improved, but glue consumption increases
Solution Approach 1:
The fourth roller (R4) acts as an intermediary press roller that applies mechanical pressure to the flap during gluing. This intermediary action enhances bonding strength without requiring excessive glue, as the pressure ensures proper adhesion with minimal adhesive material.
Solution Approach 2:
The patent changes the physical parameters of the gluing process by introducing mechanical pressure through the fourth roller. This parameter change (application of pressure) compensates for reduced glue quantity, maintaining bonding strength while reducing glue consumption.
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 solution stabilizes logs during intermediate and final winding phases, reduces glue usage, and enhances the efficiency of the gluing process, allowing for precise containment and efficient log production with less space required.
Implementation Method 1
the fourth roller (R4) is positioned to assist in the final winding phase... acting as a press roller for flap gluing
Implementation Method 2
winding rollers which impose each core to rotate about its longitudinal axis thus determining the winding of the web on the same core
Implementation Method 3
a predetermined amount of glue is distributed to allow the paper web to be bonded onto the cores
Data Source
Figure 1
Figure 2A~2D
Figure 2E~2H
AI summary
Rewinding machine for the production of logs of paper material, comprising a winding station (W) in which are fed a paper web (3) and, in sequence, more tubular cores (4), and in which station winding (W) are arranged a first, a second and a third winding roller (R1, R2, R3) cooperating with each other to wind a predetermined amount of said paper web (3) onto each core (4). The machine comprises a fourth winding roller (R4) which is connected to respective moving means adapted to arrange it in a first inoperative position (A) until the diameter of a log (L) in the winding station is lower than a first predetermined value and a second operating winding position (B) when the diameter of the log (L) being formed is equal to said first predetermined value, said moving means being controlled to maintain the fourth roller (R4) in the second operating winding position (B) until the diameter of the log reaches a second final value higher of the first predetermined value such that, in a first phase, which ends with the attainment of said first predetermined value of the diameter of the log being formed, the winding of the web (3) on the cores (4) is realized by said first, second and third winding roller (Rl, R2, R3), and, at a subsequent phase, the log is completed in cooperation by the four winding rollers ( Rl, R2, R3, R4) until said second final value of the diameter of the log is reached.