Robotic Roller Cleaning for Defect Control in High-Speed Coating
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Solution Overview
Problem
High-speed coating machines face inefficiencies due to fouling on rollers, leading to defects in the coated web, which are difficult to remove manually and pose safety risks, particularly in ATEX environments, requiring automated and controlled cleaning to maintain production quality and safety.
Innovation Solution
A robotic cleaning system with a command unit, robotic arm, and cleaning device that autonomously cleans the outer surface of rollers based on defect detection data from sensors, using a cleaning pad and solvent application controlled by a command unit to address fouling in real-time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual cleaning with polishing pad is used, then cleaning can be performed, but cleaning effectiveness is insufficient and operator safety is at risk
Solution Approach 1:
The patent replaces manual mechanical cleaning operations with an automated robotic arm system that applies cleaning pads to the roller surface. This substitution eliminates operator exposure to hazardous cleaning environments while maintaining or improving cleaning effectiveness through consistent automated pressure and motion control.
Solution Approach 2:
The cleaning system is designed to autonomously clean the roller surface without requiring operator intervention. The robotic arm automatically positions and applies cleaning pads to the roller, enabling the system to service itself and eliminating the need for manual cleaning operations in hazardous environments.
2Reliability
If production is stopped to clean rollers, then fouling can be removed, but production efficiency is reduced
Solution Approach 1:
The system performs preliminary cleaning actions by continuously or periodically cleaning the roller surface during production operation. The robotic arm is positioned to clean the roller before fouling accumulates to problematic levels, preventing web quality defects while maintaining production continuity.
Solution Approach 2:
The cleaning operation is integrated into the continuous production process, allowing cleaning to occur without stopping the web feeding mechanism. The robotic arm operates in coordination with the running production line, maintaining continuous useful action for both production and cleaning functions simultaneously.
3Extent of automation
If automated robotic cleaning is implemented, then operator safety is improved and productivity is maintained, but system complexity increases
Solution Approach 1:
The robotic arm system is designed with multi-functionality, capable of performing different cleaning operations with various pad types and configurations. This universal approach consolidates multiple cleaning functions into a single automated platform, managing system complexity while maintaining high automation benefits.
4Productivity
If high-speed coating is performed, then production efficiency is improved, but roller fouling occurs more rapidly
Solution Approach 1:
The system implements periodic cleaning cycles during high-speed coating operation. The robotic arm periodically contacts the roller surface to remove accumulating fouling, maintaining roller cleanliness throughout extended high-speed production runs without requiring speed reduction or production stoppage.
Data Source
AI summary
The invention concerns a cleaning system adapted to clean the outer surface of a roller of a coating machine adapted to coat and/or print and/or shape a layer on a web, the cleaning system comprising:a robotic arm comprising an holding organ;a cleaning device held on the holding organ, the cleaning device being adapted to clean the outer surface of the roller; anda command unit adapted to command the robotic arm and the cleaning device to carry out a cleaning task of a part of the outer surface, wherein the command unit is further adapted to receive at least one defect property and to trigger a cleaning task in accordance with each received defect property, a defect property being a property of at least one defect of the layer.