Programmable Servomotor Shell Speed Control for Fibrous Patches
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current high-speed manufacturing processes for fibrous webs in absorbent articles face inefficiencies due to the need for larger drums, which consume more energy and space, while also struggling to maintain flexibility in producing different patch lengths and pitches without distorting the shape of unbonded fibrous structures.
Innovation Solution
A method utilizing programmable servomotors with a stator comprising stationary electromagnets and movers with permanent magnets to control the speed of shells carrying fibrous material, allowing for precise formation and transfer of fibrous patches to a carrier web with varying speeds and spacings without distortion, using a modular linear motor system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If larger diameter drums are used to form unbonded fibrous webs, then different sized fibrous webs can be manufactured with different patch lengths and pitches, but energy consumption increases and space efficiency decreases
Solution Approach 1:
The patent applies a programmable servomotor system that dynamically adjusts the speed of the shell during its travel along the stationary track. The motor varies the shell's speed to control patch length and spacing without changing drum diameter, enabling flexible production on a fixed-drum system. This dynamic speed control replaces the static approach of using different drum sizes.
2Adaptability or versatility
If larger diameter drums are used to form unbonded fibrous webs, then different sized fibrous webs can be manufactured with different patch lengths and pitches, but space efficiency decreases
Solution Approach 1:
The programmable servomotor system enables a fixed-diameter drum to produce variable patch lengths and pitches through dynamic speed adjustment. This eliminates the need for multiple drum sizes, reducing the space required for drum storage and changing infrastructure while maintaining full production flexibility.
3Productivity
If conventional motor systems are used to drive shells at variable speeds, then production flexibility is limited, but system complexity and control precision are insufficient
Solution Approach 1:
The programmable servomotor system incorporates feedback control mechanisms that continuously monitor and adjust shell speed to maintain precise control during acceleration and deceleration phases. This feedback ensures that fibrous patches are deposited at exact positions and orientations, preserving shape and contour integrity even at high manufacturing speeds.
Solution Approach 2:
The system uses dynamic speed profiling where the shell accelerates and decelerates at controlled rates according to a programmed trajectory. This dynamic control prevents sudden speed changes that would distort the fibrous structure, while still enabling high overall production speeds through optimized motion profiles.
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
Enables energy-efficient production of fibrous structures on a fixed-diameter drum with flexible patch lengths and spacings, maintaining the integrity and shape of the fibrous structures during high-speed manufacturing, improving production efficiency and adaptability.
Implementation Method 1
the stator (103) comprises a plurality of stationary electromagnets and wherein the movers (60) comprise permanent magnets and wherein the variable speed of the movers (60) along the stationary track (100) is controlled by varying the current supplied to the stationary electromagnets
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The present invention relates to a method for forming and transferring an unbonded fibrous structure to a carrier, the method comprising the steps of: receiving fibrous material on a shell (50) travelling at a first speed through a receiving zone to form a fibrous patch (25); transferring the shell (50) from the receiving zone (23) to an application zone (27); applying the fibrous patch (25) to the carrier (30) travelling at a second speed through the application zone (27); and controlling the speed of the shell by a motor, the motor comprising a stator (103) and at least one mover (60); wherein the shell is driven by at least one mover (60), wherein the mover (60) maintains the shell (50) at the first speed in the receiving zone (23) and the second speed in the application zone (27), and wherein the mover (60) is mounted on a stationary track (100).