Rewinding Machine Support Rollers for Uniform Large-Reel Winding
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Solution Overview
Problem
Existing rewinding machines face issues with uneven pressure distribution and vibration during the winding of large reels, leading to thickness changes, creases, and speed limitations, especially for low-density products like paper and nonwoven fabric, due to inadequate support and tensioning systems.
Innovation Solution
A rewinding machine with a flexible web segment between carrier rollers, supported by a third roller, distributes weight evenly and maintains product stability, using an air-permeable web for conveying and suction to prevent creases and dust, allowing high-speed production without tensioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If peripheral contact winding with carrier rollers is used, then winding speed can be increased, but the pressure on the reel surface increases causing thickness changes
Solution Approach 1:
The support system is segmented into multiple carrier rollers (at least three rollers) that distribute the reel weight across multiple contact points around the reel circumference. This segmentation allows the reel to be supported evenly during high-speed winding without concentrating pressure on a single line, thus preventing thickness changes while maintaining high winding speed.
2Quantity of substance
If the reel diameter increases, then more product can be wound, but the weight increases causing excessive pressure on contact points
Solution Approach 1:
The support system transitions from line contact to distributed point contact by arranging multiple carrier rollers around the reel circumference. This dimensional change in the support geometry allows the system to handle increasing reel weights as diameter grows, distributing the load across multiple rollers rather than concentrating it on a single contact line.
3Productivity
If the reel reaches large diameter, then production capacity increases, but vibration occurs limiting winding speed
Solution Approach 1:
The system utilizes controlled mechanical vibration through the arrangement and movement of multiple carrier rollers to stabilize the reel during high-speed winding. The rollers are positioned to create damping effects that counteract harmful vibrations, allowing the reel to maintain stability even at large diameters and high production speeds.
4Stress or pressure
If multiple contact points are used to support the reel, then weight distribution improves, but the system complexity increases
Solution Approach 1:
The carrier rollers serve multiple functions simultaneously: they support the reel weight, distribute pressure evenly, enable high-speed winding, and dampen vibrations. This multi-functionality reduces the need for additional specialized components, keeping the system relatively simple despite the multiple contact points required for optimal performance.
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
The solution ensures stable, high-speed winding with reduced pressure and vibration, preserving product quality by maintaining thickness and preventing creases, while facilitating dust removal and adjusting speed for different densities.
Implementation Method 1
a web, forming at least one web loop, made of a material with an air-permeable texture
Implementation Method 2
one or more suction boxes placed under the web to retain the ribbon-like product
Data Source
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AI summary
The present invention relates to a rewinding machine equipped with a support system for the reel and the ribbon-like product. In particular, the invention relates to a rewinding machine (1) for a ribbon-like product (N), comprising: - a fixed support structure which supports an unwinding unit (SV) and a rewinding unit (RB); - an independent first carrier roller (2), movable along a direction parallel to a support surface of the rewinding machine (1); - a second independent carrier roller (4), movable in the opposite direction with respect to the first carrier roller (2); - a third roller (3), placed between the first (2) and second (4) carrier rollers and movable integrally with the first carrier roller (2); - a set of driving rollers (110) placed along a path between the unwinding unit (SV) and the rewinding unit (RB); - a web (10), forming at least one loop, made of a material with an air-permeable texture, said web (10) unwinding between the second carrier roller (4), the third roller (3), and the set of driving rollers (110); - one or more suction boxes (6) placed under the web (10) to retain the ribbon-like product (N).