Roll Handling Device for Uninterrupted Packaging Material Supply
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Solution Overview
Problem
Existing methods for handling flat and/or film material wound on rolls often result in interruptions during packaging operations due to the need for roll changes, lacking a high degree of automation and continuous material supply.
Innovation Solution
A method and device that utilize a system with at least two installation positions for roll handling, where new rolls are inserted while the packaging operation continues from another roll, using a handling device and sensors for orientation and rotation detection, and a control unit for automated operation, ensuring continuous or quasi-continuous packaging without interruptions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single roll is used for packaging material supply, then the device structure is simple, but the packaging operation must be interrupted during roll changes
Solution Approach 1:
The packaging machine is divided into multiple installation positions (at least two) for rolls, allowing independent operation of each position. This segmentation enables one position to continue packaging while another undergoes roll change, eliminating interruptions and maintaining continuous productivity.
2Extent of automation
If manual roll changing is used, then the device structure is simple, but the automation level is low and efficiency is reduced
Solution Approach 1:
The system enables automated roll handling where the packaging machine itself performs roll changes through integrated handling devices, sensors for orientation detection, and control units. This self-service automation eliminates manual intervention, increases efficiency, and maintains continuous operation without requiring complex external automation systems.
3Productivity
If roll changes are performed frequently, then material supply is maintained, but packaging operations are interrupted and productivity decreases
Solution Approach 1:
The packaging machine maintains continuous useful action by operating with at least two installation positions simultaneously. While one position undergoes roll change, the other continues packaging operations without interruption. This ensures uninterrupted material supply and eliminates downtime, maintaining constant productivity throughout the process.
4Extent of automation
If automated sensors and control units are added for roll orientation detection, then automation level increases, but device complexity increases
Solution Approach 1:
Manual mechanical orientation checking and adjustment is replaced with automated sensors that detect roll orientation and control units that automatically adjust roll positions. This substitution eliminates manual intervention, increases automation level, and streamlines the roll changing process while the added complexity is offset by the elimination of manual operations.
Data Source
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AI summary
The invention relates to a method and to a device (1) for handling flat and/or film material that is wound onto rolls (5) and that serves as packaging material for packaging piece goods, multipacks, or similar assemblies of articles. In order to maintain packaging operation, at least approximately completely unwound and/or used up rolls (5) are removed from at least one installation position (EB1; EB2) of a packaging machine (3) in alternation and in each case a new roll (5) having flat and/or film material is installed in the installation position in question on the packaging machine. After each installation, an outer layer (15) of the new roll (5) is drawn off in the region of the free end of said outer layer and is connected to a segment of a material web of a further roll (5), which material web is guided in the packaging machine (3), in order to form an uninterrupted material web. During the installation of a new roll (5) and during the connection, the flat and/or film material of the further roll (5) has not yet been completely used up, and therefore flat and/or film material is unwound from at least one roll (5) of the installation position (EB1; EB2) without interruption for continuous packaging operation. Furthermore, at least approximately completely unwound and/or used up rolls (5) are preferably detected by sensor and independently replaced with new rolls (5) having flat and/or film material by means of a handling device.