Roll Loading Rail and Lifting Structure to Prevent Roll Drops
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Solution Overview
Problem
Existing roll handling systems in secondary battery manufacturing cause material defects and operator accidents due to rolls falling during replacement.
Innovation Solution
An apparatus for loading and unloading rolls that includes a roll support portion, a traveling rail, a moving frame, and a roll attaching and detaching unit, which enables automated movement and attachment/detachment of rolls without human intervention, using lifting units and clamps to secure and transfer rolls between unwinders and support portions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If a robot arm is used to transport rolls, then automation is improved, but the robot arm cannot grip the roll tightly causing the roll to fall
Solution Approach 1:
A suction cup is introduced as an intermediary between the robot arm and the roll. The suction cup creates a vacuum connection that enables reliable gripping of the roll by the robot arm, solving the problem of the roll falling during automated transport.
2Force
If a forklift is used to move rolls, then lifting capability is improved, but the forklift cannot enter the production line to pick up rolls
Solution Approach 1:
The roll moving apparatus is divided into separate functional modules: a lifting unit with lifting rails that can vertically move rolls, and a traveling rail system that transports rolls along the production line. This segmentation allows the apparatus to lift rolls like a forklift while also being able to access and transport rolls within the production line space.
Solution Approach 2:
A traveling rail system acts as an intermediary between the lifting unit and the roll unwinder. The traveling rail receives rolls from the lifting unit and transports them to the unwinder, enabling the apparatus to both lift rolls and access the production line effectively.
3Adaptability or versatility
If manual handling is used, then flexibility is improved, but labor intensity increases and efficiency decreases
Solution Approach 1:
The apparatus employs dynamic components including a movable traveling rail that can move horizontally along the production line, and a lifting unit that can vertically move rolls. This dynamic design provides flexibility in handling rolls at different positions while automating the process to improve productivity and reduce labor intensity.
4Device complexity
If conventional loading methods are used, then simplicity is improved, but the roll cannot be stably supported during unwinding
Solution Approach 1:
The lifting unit is designed to vertically move rolls along lifting rails, providing stable vertical support. The traveling rail system provides stable horizontal support during transport. This dual-directional support system ensures the roll remains stably supported during both loading and unwinding operations.
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
Prevents material defects and operator accidents by ensuring safe and automated roll handling, reducing the risk of rolls falling during replacement.
Implementation Method 1
a suction unit which generates negative pressure
Implementation Method 2
a lifting unit configured to move up and down a disposed roll
Implementation Method 3
a first traveling rail disposed on one side of the roll unwinder; a moving frame movably installed on the first traveling rail
Data Source
Figure 1
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Figure 3
AI summary
An apparatus for loading and unloading a roll includes a roll support portion disposed adjacent to a roll unwinder; a first traveling rail disposed on one side of the roll unwinder; a moving frame movably installed on the first traveling rail; and a roll attaching and detaching unit movably installed on the moving frame, wherein the roll support portion includes a lifting unit configured to move up and down a disposed roll, and wherein the roll attaching and detaching unit includes a moving plate moving on the moving frame, and a main body portion rotatably installed on the moving plate.