Rewinding Machine Movable Roller Winding Accuracy
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Solution Overview
Problem
Existing automatic continuous surface rewinding machines for producing rolls of web material, such as toilet paper or kitchen towels, face challenges in ensuring consistent and reproducible winding cycles, particularly due to variations in material properties and core features, which affect the accuracy and reliability of the winding process.
Innovation Solution
An automatic continuous surface rewinding machine with four rollers, where the first, second, third, and fourth rollers form two winding cradles, with the third and fourth rollers having movable axes to follow the roll and core movement, and a severing member cooperating with the third roller to pinch and sever the web material using a linear element or pressing members, ensuring continuous feeding and precise winding without stopping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a fixed-axis winding roller is used, then the machine structure is simpler, but the winding accuracy and reproducibility deteriorate due to inability to follow roll and core movement
Solution Approach 1:
The patent applies the dynamics principle by transforming the fixed-axis winding roller into a movable-axis roller that can dynamically follow the movement of the roll and core during the winding process. This allows the roller to maintain optimal contact and positioning, thereby improving winding accuracy and reproducibility without requiring an overly complex multi-roller system.
2Reliability
If the web material is severed by speed difference, then the severing mechanism is simpler, but the severing reliability deteriorates due to material property variations
Solution Approach 1:
The patent replaces the mechanical speed-difference severing system with a controlled mechanical severing mechanism that actively manages the severing process. This substitution ensures reliable severing across different material properties by providing direct control over the severing action rather than relying on indirect speed differential effects.
3Manufacturing precision
If four rollers with movable axes are used, then the winding cycle control is improved, but the device complexity and cost increase
Solution Approach 1:
The patent implements controlled movement of the winding roller axes to follow the roll and core during winding. This dynamic positioning capability provides superior winding cycle control and reproducibility while avoiding the need for all four rollers to have complex movable axes, thus balancing precision requirements with device complexity.
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 configuration allows for high-frequency winding of web material rolls with improved accuracy and reliability, independent of web material feed speed changes, ensuring consistent roll formation and efficient operation by synchronizing the movement of the third winding roller and severing member, thus enhancing the reproducibility and quality of the winding process.
Implementation Method 1
a severing member (23) cooperating with the third winding roller (7) and acting on the web material (N) in a portion comprised between the third winding roller (7) and the roll (L2) being formed in the second winding cradle (10), so as to pinch the web material (N) against the third winding roller (7)
Data Source
AI summary
The rewinding machine includes a first winding cradle, formed between a first winding roller, a second winding roller and a third winding roller, and a second winding cradle formed between the first winding roller, the second winding roller and a fourth winding roller. The first winding roller and the second winding roller define a nip through which nip the winding cores, around which the web material is found, pass and the web material is fed towards a roll being formed in the second winding cradle. A severing member is furthermore provided, acting on the web material between a winding core and the nip, to sever the web material thus generating a tail edge of a completed roll and a leading edge of a new roll to be wound.