Rewinding Machine Integrating On-Line Core Formation
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Solution Overview
Problem
The high production rates of rolls of weblike materials, such as toilet paper and kitchen towels, require multiple core-winders along the production line, leading to increased costs and encumbrance, and the traditional method of using cardboard cores necessitates gluing and subsequent disposal issues.
Innovation Solution
A method and rewinding machine that form winding cores directly on the production line using sheetlike materials, which are lightweight and can be made without glue, allowing for continuous winding and easy recycling, eliminating the need for core-winders and reducing material costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional core-winders with forming spindles are used to produce winding cores, then the production of rolls can be maintained, but the machine complexity increases and encumbrance increases when multiple core-winders are needed for high production rates
Solution Approach 1:
The invention extracts the core-winding function from the traditional core-winder machine and integrates it directly into the rewinding machine. The sheetlike material is fed and wound around the forming spindle within the rewinding machine itself, eliminating the need for separate core-winders and reducing overall system complexity while maintaining high productivity
Solution Approach 2:
The invention merges the core formation process with the roll winding process by integrating the sheetlike material feeding mechanism and forming spindle into the rewinding machine. This combination allows both functions to be performed in one machine, reducing the number of machines needed and simplifying the production line
2Strength
If cardboard or other material strips are used to form winding cores, then the cores provide structural support, but gluing is required which increases manufacturing complexity and creates disposal issues
Solution Approach 1:
The invention uses thin sheetlike material to form winding cores that are lightweight and easily disposable. These cores can be made from recyclable materials and do not require complex gluing processes, simplifying manufacturing and reducing environmental impact while still providing adequate structural support during the winding process
Solution Approach 2:
The invention changes the material parameters from traditional thick cardboard strips to thin sheetlike material. This parameter change reduces the need for gluing and simplifies the manufacturing process while maintaining sufficient structural integrity for the winding operation through optimized material selection and winding tension control
3Productivity
If high production rates are achieved with traditional core-winders, then more rolls can be produced per unit time, but the encumbrance and space requirements increase due to multiple core-winders needed along the production line
Solution Approach 1:
The invention combines the core formation function with the roll winding function in a single integrated machine. This merger eliminates the need for multiple separate core-winders along the production line, reducing space requirements and encumbrance while maintaining high production rates through continuous operation
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 approach reduces production costs, minimizes the need for gluing, and facilitates easier disposal of the winding cores, while maintaining high production rates without interrupting the continuous winding process.
Implementation Method 1
a suction opening (45) arranged to generate a suction effect for retaining the sheetlike material (F) on the forming spindle (M)
Data Source
Figure 1A
Figure 1B
Figure 1C
AI summary
Described herein is a rewinding machine for the production of rolls (L) of weblike material around winding cores, including a path for the weblike material (N) and a winding area, in which said weblike material is wound in rolls. The machine moreover comprises a feeder for feeding a sheetlike material (F) towards the path of the weblike material, and forming members (13, 15) for rolling a length of said sheetlike material and forming therewith a winding core around which a roll of weblike material is formed.