Automatic Sleeving Splicer with Butt Splice and Tape Application
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Solution Overview
Problem
Existing splicing systems for rolls of sleeve material are inefficient and lack automation, leading to disruptions in the packaging market due to manual operations and inconsistent product repeat lengths.
Innovation Solution
An automatic sleeving splicer system that performs an automatic cut and butt splice with tape application on both sides of the splice joint, ensuring consistent product repeat lengths by using guide rolls, nip bars, and optical registration for precise alignment and operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual splicing operations are used, then device complexity is reduced, but productivity decreases and manufacturing precision deteriorates
Solution Approach 1:
The splicing system is divided into distinct functional modules: a cutting module with a blade for cutting the expiring web, a splicing module with a splicing bar for joining webs, and a tape application module with applicators. Each module operates independently but coordinates through the control system, allowing automated high-speed splicing while managing complexity through functional segmentation.
Solution Approach 2:
The system replaces manual mechanical splicing operations with an automated control system that uses sensors to detect web positions and a control unit to coordinate the timing and movement of cutting and splicing operations. This substitution of manual control with automated mechanical and electronic control enables higher productivity and precision.
2Manufacturing precision
If manual splicing operations are used, then device complexity is reduced, but manufacturing precision deteriorates
Solution Approach 1:
The system incorporates sensors that detect the position of registration marks on the sleeve material and provide feedback to the control system. The control system uses this feedback to adjust the splicing timing and position, ensuring consistent product repeat lengths. The feedback loop enables precise control of the splicing operation to maintain manufacturing precision.
Solution Approach 2:
The system performs preliminary alignment of the new web with the expiring web using registration marks before the actual splicing occurs. The control system detects these marks in advance and positions the webs correctly, ensuring precise alignment and consistent repeat lengths before the cutting and joining operations take place.
3Productivity
If automatic splicing is implemented, then productivity increases, but device complexity increases
Solution Approach 1:
The system enables continuous operation by automatically splicing the expiring web to a new web without stopping the packaging machine. The cutting, splicing, and tape application operations occur while the machine continues running, maintaining continuous production flow and eliminating downtime associated with manual roll changes.
Solution Approach 2:
The system combines multiple functions into an integrated automated splicing unit: web cutting, web alignment, web joining, and tape application all occur in sequence within a single coordinated operation. This merging of functions into one automated system achieves continuous production while managing complexity through integration rather than separate manual operations.
4Manufacturing precision
If automatic cut and splice operation is performed, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The system uses registration marks on the sleeve material as intermediaries for alignment. Sensors detect these marks, and the control system uses the mark positions as reference points to precisely align the new web with the expiring web before splicing. This intermediary reference system enables high precision alignment without requiring complex direct measurement systems.
Data Source
AI summary
A system and method for automatic splicing of rolls of sleeve material used in various packaging markets is provided. The system will automatically splice the prepared end of a new roll onto the expiring end of the prior roll. The system performs an automatic cut and splice operation resulting in a butt splice of the two rolls with tape applied to both sides of the splice joint. The splice can be done in-registration to provide a consistent product repeat length between expiring and new rolls.