Rotatable Roll With Pockets For Variable Length Article Folding
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Solution Overview
Problem
Conventional manufacturing processes for disposable absorbent articles face challenges in increasing transport speed without enlarging rolls or motors, which can be costly and space-consuming, and struggle to maintain aligned edges during folding operations without mechanical holding means.
Innovation Solution
A system utilizing a rotatable roll with protrusions and pockets, combined with vacuum conveyors driven by variable speed motors, to transfer and fold articles efficiently, allowing for adjustable article length and alignment without mechanical holding, thereby enhancing transport speed and edge alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the rotational speed of the roll is increased to increase article transport rate, then productivity is improved, but larger and more powerful drive motors are required which increase cost and floor space
Solution Approach 1:
The roll surface is segmented into protrusions and pockets, allowing articles to be positioned in pockets during transport. This segmentation enables the roll to accommodate variable length articles while maintaining consistent transport speed, eliminating the need to increase motor power to handle different article configurations.
Solution Approach 2:
The system dynamically adjusts article positioning by transferring articles between the roll surface and vacuum conveyors. This dynamic adjustment allows the same roll and motor configuration to handle articles of variable lengths by changing the articole arrangement rather than changing the motor size.
2Adaptability or versatility
If the roll circumference is increased to accommodate longer articles, then adaptability is improved, but the roll size and motor requirements increase
Solution Approach 1:
The roll surface is divided into multiple pockets that can accommodate articles of different lengths. By positioning articles in specific pockets and using variable speed vacuum conveyors, the system can handle articles of various lengths without requiring a larger roll circumference.
Solution Approach 2:
The system changes the operational parameters by using variable speed vacuum conveyors to transfer articles at different speeds to and from the roll. This allows the same roll circumference to effectively accommodate articles of different lengths by adjusting the transfer timing and speed rather than changing the physical roll size.
3Manufacturing precision
If variable speed servo motors are used to control vacuum conveyors, then manufacturing precision is improved, but motor inertia increases potentially offsetting speed and acceleration benefits
Solution Approach 1:
The system replaces heavy mechanical holding means with a vacuum-based transfer system. The vacuum conveyors use suction to hold and transfer articles, eliminating the need for heavy mechanical clamps or holders. This substitution reduces overall system inertia while maintaining precise control through variable speed motors.
Solution Approach 2:
The vacuum conveyors act as intermediaries between the roll and the final product. They provide precise speed control to ensure articles are transferred at the correct timing and position, achieving edge alignment without requiring the main drive motor to have excessive inertia for precise positioning.
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 solution enables increased article transport rates without enlarging rolls or motors, maintains aligned edges, and allows for flexible article lengths, reducing the need for frequent roll replacements and minimizing mechanical holding requirements.
Implementation Method 1
a first vacuum conveyor including a movable surface configured to receive at least a portion of the leading end of the article from the rotating roll
Implementation Method 2
a second vacuum conveyor including a movable surface for engaging the leading end of the article and applying a peel force thereto
Data Source
AI summary
An apparatus for folding articles advancing in a machine direction including a rotatable roll having a roll surface, at least one protrusion that defines an outermost surface of the roll and at least one pocket that defines an innermost surface of the roll. The apparatus also includes a first and second vacuum conveyor assembly, each comprising two vacuum conveyors. The roll and the vacuum conveyor assemblies are cooperatively configured to fold an article.