Roll Tail Sealing With Laser Detection of Tail End Position

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Solution Overview

Problem

Existing methods for determining the circumferential position of the tail end on a roll of convolutely wound web are energy-intensive, require significant setup time and adjustment, reduce production rates, and introduce process upsets.

Innovation Solution

A method utilizing a laser gauging sensor to directly measure the distance from the sensor to the log surface and detect the tail end position, eliminating the need for vacuum or air blasts, and allowing for reduced energy consumption and faster setup times.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If vacuum or air blasts are used to determine tail end position, then the tail end position can be detected, but energy consumption increases and setup time increases

Engineering Contradiction:

Improvetail end position detectionVSAvoidenergy consumption

Core Design Contradiction:

Measurement precisionVSUse of energy by moving object

Solution Approach 1:

The patent replaces the mechanical/pneumatic system (vacuum boxes and air blasts) with an optical sensing system (laser gauging sensor). The laser sensor directly measures the distance to the log surface to detect tail end position without requiring vacuum or air blasts, thereby eliminating the associated energy consumption while maintaining detection capability

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent extracts and eliminates the vacuum and air blast subsystems from the tail detection process. By using only the laser gauging sensor to detect tail end position, the system removes the energy-intensive vacuum generation and air blasting components, reducing overall energy consumption while preserving the essential function of tail position detection

Inventive Principle:

Principle #2Taking out (Extraction)

2Measurement precision

If vacuum or air blasts are used to determine tail end position, then the tail end position can be detected, but setup time increases

Engineering Contradiction:

Improvetail end position detectionVSAvoidsetup time

Core Design Contradiction:

Measurement precisionVSLoss of time

Solution Approach 1:

The patent replaces the complex mechanical setup involving vacuum boxes and air blast adjustments with a simple optical laser sensor system. The laser sensor requires minimal setup and calibration, eliminating the time-consuming adjustment procedures associated with pneumatic and vacuum systems while maintaining accurate tail end position detection

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The laser gauging sensor is pre-configured to directly measure tail end position without requiring preliminary activation of vacuum or air blast systems. This eliminates the setup time needed to prepare and adjust these auxiliary systems, allowing immediate tail position detection upon sensor installation

Inventive Principle:

Principle #10Preliminary action

3Reliability

If traditional tail sealing methods are used, then the tail can be sealed, but production speed decreases due to energy-intensive processes

Engineering Contradiction:

Improvetail sealing reliabilityVSAvoidproduction speed

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent replaces energy-intensive mechanical and pneumatic systems with an optical laser measurement system for tail position detection. This streamlined approach eliminates the time delays associated with activating and adjusting vacuum and air blast systems, thereby increasing production speed while maintaining the reliability needed for accurate tail sealing

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The laser gauging sensor enables continuous, real-time measurement of tail end position without interrupting the production flow with energy-intensive vacuum or air blast operations. This continuous measurement capability allows for faster cycle times and improved production speed while maintaining sealing reliability through accurate position detection

Inventive Principle:

Principle #20Continuity of useful action

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

This approach reduces operating costs, increases production speed, and enhances process reliability by minimizing energy consumption and setup times while maintaining high production rates.

Implementation Method 1

A method utilizing a laser gauging sensor to directly measure the distance from the sensor to the log surface and detect the tail end position

Methodology Applied

Scientific EffectLaser: Laser

Data Source

PatentUS20250361107A1Method and Apparatus for Tail Sealing of Roll Products

Publication Date: 2025.11.27 BW CONVERTING INC

AI summary

A circumferential location of a tail end of a log of convolutely wound web material is determined by rotating the log in a stationary position and a diameter of the log is sensed with a sensor at a plurality of times while rotating the log in the stationary position. A plurality of signals corresponding to the diameter of the log at the plurality of times are generated. The signals corresponding to the diameter of the log at the plurality of times a compared. A change in the signals corresponding to the diameter of the log at the plurality of times is detected and associated with the circumferential location of the tail end of the log.