Servo-Controlled Article Transfer Apparatus for Wrinkle-Free Diaper Core Placement
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Solution Overview
Problem
Existing apparatuses for reorienting absorbent pads in disposable product manufacturing are limited in flexibility, as they can only receive and place inserts at similar pitches and stretch them in the cross-direction, leading to distortion and wrinkling during transfer operations.
Innovation Solution
The apparatus uses servo-motor electronic cam profiling to match web velocities and includes a canted pitch changer with separately driven segments to stretch articles in both cross and machine directions, allowing for different input and output pitches and reducing wrinkling by optimizing motion profiles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If an apparatus receives and places inserts at similar pitches, then the transfer operation is simple, but the flexibility in product configurations is limited
Solution Approach 1:
The apparatus employs variable speed conveyors that can operate at different pitches and speeds independently. The first conveyor receives inserts at one pitch while the second conveyor places them at a different pitch, with each conveyor's speed being independently controllable. This dynamic speed adjustment capability enables flexible product configurations without requiring a complex reconfiguration of the entire apparatus.
2Adaptability or versatility
If an apparatus stretches inserts only in the cross-direction, then the device structure is simple, but the ability to handle various product configurations is limited
Solution Approach 1:
The apparatus extends the stretching capability from only the cross-direction to include both cross-direction and machine-direction stretching. By configuring the first and second conveyors to move in different directions and at different speeds, the system can stretch inserts in multiple dimensions, enabling handling of various product configurations including different insert lengths and orientations.
3Manufacturing precision
If web velocities at pick-up and lay-down points are not matched, then the transfer operation is simple, but wrinkling and distortion occur during transfer
Solution Approach 1:
The apparatus incorporates a control system that monitors and coordinates the speeds of the first and second conveyors. By providing feedback control on the web velocities at the pick-up and lay-down points, the system automatically adjusts conveyor speeds to match appropriate velocities, preventing wrinkling and distortion during the transfer operation while maintaining manufacturing precision.
Data Source
AI summary
An apparatus for transferring articles such as absorbent cores or disposable diaper chassis components from a rotary mechanism, such as a pad turner, to a linear mechanism, such as a conveyor, for further processing. The invention provides a device for picking an article from the outside of a toroidal surface, thence extending transversely under tension the article to be transferred so that at the point of deposition the article is held flat and at full length. Further, the invention allows for apparatus to match the velocity of both the first and second transfer points, even if these velocities are not the same. The device is of particular benefit where an article to be transferred is subject to internally biasing elastic forces.