Robotic Unwind Stand for Continuous Web Material Splicing

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Solution Overview

Problem

Current manufacturing processes for disposable absorbent articles like diapers and catamenial devices face challenges with manual material handling, requiring significant operational effort, floor space, and increased costs due to the need for continuous roll changes and manual loading of convolutely wound web materials, which limits production efficiency and agility.

Innovation Solution

A robotic unwind stand equipped with positionable roll grasping apparatuses, such as 6-axis robots, that automatically load, splice, and unwind convolutely wound rolls, ensuring continuous web material supply to downstream manufacturing processes at constant velocity and tension, reducing manual intervention and optimizing floor space usage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If manual operation is used for material handling and loading, then operational flexibility is maintained, but operational effort and cost increase significantly

Engineering Contradiction:

Improveoperational effortVSAvoidmanual operation

Core Design Contradiction:

Ease of operationVSExtent of automation

Solution Approach 1:

The robotic unwind stand performs material handling, loading, and splicing operations autonomously without human intervention. The system serves itself by automatically grasping rolls, positioning them on mandrels, and executing splicing procedures, thereby eliminating the need for manual operational effort while maintaining continuous manufacturing processes

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent replaces manual mechanical operations with an automated robotic system equipped with roll grasping apparatus and splicing mechanisms. The robotic system uses programmed mechanical actions to perform tasks previously done by hand, substituting human-operated mechanical systems with automated ones to reduce operational effort and cost

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Productivity

If additional floor space is allocated for automation solutions, then material handling efficiency improves, but available floor space decreases

Engineering Contradiction:

Improvematerial handling efficiencyVSAvoidfloor space

Core Design Contradiction:

ProductivityVSArea of stationary object

Solution Approach 1:

The robotic unwind stand integrates multiple functions including roll grasping, positioning, splicing, and unwinding operations into a single compact platform. This multi-functional design allows the system to perform various material handling tasks without requiring separate dedicated spaces for each operation, thereby improving productivity while minimizing floor space requirements

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent combines the roll loading mechanism, splicing apparatus, and unwinding system into an integrated robotic workstation. By merging these previously separate functions into one unified system, the design achieves high material handling efficiency within a compact footprint, reducing the total floor space needed compared to distributed manual handling stations

Inventive Principle:

Principle #5Merging (Combining)

3Productivity

If manual loading of rolls is performed, then equipment complexity is reduced, but production speed and continuity are limited

Engineering Contradiction:

Improveproduction speedVSAvoidequipment complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The robotic system autonomously performs roll loading and splicing operations without human assistance. The system self-manages the entire process from grasping the roll, positioning it on the mandrel, to executing the splice and resuming unwinding, thereby enabling continuous high-speed production while managing equipment complexity through integrated automation

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent implements continuous operation by eliminating manual intervention points in the material handling process. The robotic system maintains uninterrupted roll changes and splicing operations, ensuring continuous web material supply to the converting equipment. This continuity enables sustained high production speeds without the downtime associated with manual roll changes

Inventive Principle:

Principle #20Continuity of useful action

4Reliability

If more web material rolls are stored for continuous operation, then production continuity is improved, but floor space requirements increase

Engineering Contradiction:

Improveproduction continuityVSAvoidfloor space

Core Design Contradiction:

ReliabilityVSArea of stationary object

Solution Approach 1:

The robotic unwind stand extracts and processes rolls on-demand rather than requiring large inventory storage. The system takes rolls from a compact storage area, loads them sequentially, and maintains continuous operation through automated splicing. This extraction approach ensures production continuity while minimizing the floor space needed for roll storage compared to bulk storage requirements

Inventive Principle:

Principle #2Taking out (Extraction)

Data Source

PatentUS9926160B2Robotic unwind stand

Publication Date: 2018.03.27 PROCTER & GAMBLE CO

AI summary

A web unwind stand for obtaining, loading, splicing, and unwinding convolutely wound rolls of web material and forwarding the web material unwound from each of the convolutely wound rolls uninterruptedly to a downstream apparatus is disclosed. The unwind stand comprises splicing means, a first positionable roll grasping apparatus for obtaining and disposing a first of the convolutely wound rolls proximate to, and relative to, the splicing means, and, second positionable roll grasping apparatus for obtaining and disposing a second of the convolutely wound rolls proximate to, and relative to, the splicing means.