Splicing Device for Plastic Film Rolls
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Solution Overview
Problem
Existing methods for changing rolls of web-like flat material in packaging machines require frequent manual intervention and limited storage volume due to the need for frequent roll changes, as they can only handle one reserve roll at a time, leading to inefficient operation and ergonomic challenges.
Innovation Solution
A splicing device with at least three unwinding devices and displaceable sealing bars, along with a controllable clamping device, allows for automated switching between multiple rolls, enabling seamless transition and extended machine operation without manual intervention by fixing and welding film ends to ensure continuous film supply.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If only one reserve roll is used at a time for automatic web welding, then the device complexity is reduced, but the storage volume of film web material is limited and frequent roll changes are necessary
Solution Approach 1:
The system divides the film supply into multiple independent rolls (first roll, second roll, third roll) that can be independently managed. Each roll can be loaded and unloaded separately, allowing multiple rolls to be stored simultaneously without increasing the complexity of the welding mechanism itself.
Solution Approach 2:
The patent introduces a temporal dimension to the roll management system by implementing a queue-based approach where rolls are loaded in advance and processed sequentially. This allows multiple rolls to be stored and managed through time-based automation rather than spatial complexity.
2Quantity of substance
If multiple rolls are stored to increase storage volume, then the quantity of film web material increases, but the device complexity increases due to the need to manage multiple rolls
Solution Approach 1:
The system implements automatic roll changing and welding operations without requiring manual intervention. The control unit automatically manages the sequence of rolls, triggers welding operations, and coordinates the loading and unloading of rolls, allowing the system to serve itself rather than requiring complex manual control mechanisms.
Solution Approach 2:
Rolls are loaded and positioned in advance before they are needed. The system maintains a queue of pre-loaded rolls and automatically processes them in sequence, eliminating the need for complex real-time decision-making and reducing the operational complexity of managing multiple rolls.
3Extent of automation
If rolls are located on a lower machine level for automatic web welding, then the automation of web welding is achieved, but the ergonomic conditions for handling film rolls deteriorate
Solution Approach 1:
The system separates the automation function (web welding) from the handling function (roll loading and unloading). The welding operation is automated at the lower level while the roll handling can be performed manually at an ergonomic height, dividing the tasks into distinct functional zones.
Solution Approach 2:
The patent introduces an intermediary mechanism (the control unit and automated welding system) that bridges the gap between manual roll handling and automated web welding. This intermediary layer allows manual intervention for roll handling while maintaining automation for the welding process.
4Volume of stationary object
If the maximum roll diameter is limited due to cramped space, then the storage volume per roll is reduced, but the roll changing frequency increases
Solution Approach 1:
The system transitions from a single-roll storage model to a multi-roll queue model, utilizing temporal dimensionality to extend the effective storage capacity. Instead of increasing the diameter of a single roll, the system stores multiple rolls with smaller diameters and processes them sequentially over time.
Solution Approach 2:
Multiple rolls are loaded and prepared in advance in a queue configuration. This preliminary loading allows the system to maintain a continuous supply of film material without requiring large individual roll diameters, as rolls are pre-positioned and ready for sequential processing.
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 uninterrupted machine cycles for several hours without manual intervention, allows for larger roll diameters, and increases storage volume by enabling the use of multiple rolls, reducing the need for frequent operator-assisted roll changes and improving ergonomic handling.
Implementation Method 1
at least three sealing bars (20, 24a, 24b) which are arranged to be displaceable within an approximately common plane... Each of the at least three sealing bars (20, 24a, 24b) can be pressed against a respective adjacent sealing bar by a corresponding pressure cylinder (26), so that the film ends (9-1, 9-2, 9-3, 9-4) of the film rolls (1, 2, 3, 4) are clamped and fixed at the same time
Implementation Method 2
a welding device (12) which welds the film web (8-1) of the almost empty, used roll (1) to the film web (8-2) of the new roll (2)
Implementation Method 3
Each of the at least three sealing bars (20, 24a, 24b) can be pressed against a respective adjacent sealing bar by a corresponding pressure cylinder (26)
Data Source
Figure 1
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Figure 3
AI summary
The invention relates to a splicing device (13) and a method for transporting and feeding plastic film (8) to a processing station for packaging articles by wrapping them with the plastic film (8) and optionally subsequently shrinking the film. This device includes a film roll supply with at least three separate film rolls (1-6) that can be fed successively to a conveyor, as well as a fixing and fastening device (20, 24, 26) arranged between the conveyor and the film rolls (1-6) for fixing the film ends of the still-full film rolls (2-6) and for controllably fastening one of the film ends of one of the full film rolls (2-6) to the film web leading to the processing station.