Rewinding Machine Web Support for Even Reel Pressure
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Solution Overview
Problem
Existing rewinding machines for ribbon-like products face issues with uneven distribution of contact pressure, vibration, and speed limitations, leading to quality degradation and increased complexity, especially for large reels and low-density materials.
Innovation Solution
A rewinding machine with a flexible web segment between carrier rollers, allowing for even weight distribution and adjustable speed control, using a third roller to support the reel and a web loop for conveying the product without tensioning, combined with suction boxes for residue removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If carrier rollers are used to support the reel, then the reel can be fed during rotation, but the increase in reel weight increases pressure on the contact line with the feeding roller, resulting in change of thickness of the ribbon-like product
Solution Approach 1:
The support function is segmented between the carrier rollers and the elastic belt. The elastic belt acts as an intermediate support element that distributes the reel weight across multiple contact points along its length, preventing concentration of pressure on the contact line between the feeding roller and reel surface, thus maintaining product thickness uniformity while enabling continuous winding
Solution Approach 2:
The elastic belt serves as an intermediary element between the carrier rollers and the reel. It transfers the support function from discrete roller contact points to a distributed沿-length support system, mediating the weight distribution and eliminating direct high-pressure contact lines that cause product deformation
2Manufacturing precision
If additional supports are added to lightening the load on the reel surface, then pressure can be reduced, but the weights involved for large reels are of several tons and such supports are not sufficient
Solution Approach 1:
The elastic belt performs multiple functions simultaneously: it supports the reel weight, distributes the load across the reel surface, prevents product deformation, and enables high-speed winding without requiring complex additional support structures. This multi-functional element resolves the contradiction by providing comprehensive support with a single integrated component
3Productivity
If the reel diameter increases, then more product can be wound, but the movable roller leaves a large segment of the reel unsupported, preventing good control
Solution Approach 1:
The elastic belt provides locally distributed support quality along the entire length of the belt-reel contact zone. As the reel diameter increases, the belt naturally conforms to the larger curvature while maintaining continuous contact, ensuring that every segment of the reel surface receives appropriate support and control, unlike discrete roller systems that create unsupported gaps
4Productivity
If higher winding speeds are used to meet market requirements, then productivity increases, but physical limits on dynamics are reached due to reel density, eccentricity, and vibrations
Solution Approach 1:
The elastic belt provides beforehand cushioning by absorbing vibrations and dynamic imbalances before they can propagate through the winding system. Its elastic properties allow it to compensate for reel eccentricity and density variations, damping oscillations and preventing vibration-related failures that would limit winding speed, thus enabling higher speeds while maintaining reliability
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
Enables high-speed production of stable, crease-free reels with preserved product quality, reducing specific pressure and vibrations, and eliminating the need for additional tensioning devices, while maintaining product integrity and reducing fiber dispersion.
Implementation Method 1
The web segment (10t) unwinds between the second carrier roller (4), the third roller (3)... The ribbon-like product (N) is conveyed... by means of a web segment which supports the weight of the reel during the growth
Implementation Method 2
one or more suction boxes placed under the web to retain the ribbon-like product
Data Source
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).