Static Control in Paper Winding via Flexible Belt Deflection
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Solution Overview
Problem
Existing methods for winding tissue webs into rolls at high speeds face challenges with web stability and control, leading to uneven rolls and inefficient transfers, particularly due to issues with vacuum boxes that are prone to plugging and safety hazards, and require complex dust removal systems.
Innovation Solution
An apparatus and method using an endless flexible belt with a displacement sensor to control pressure and static charge, ensuring the tissue web is securely held along its entire length, with static measurement probes and induction devices to maintain optimal static charge levels for improved web control and transfer efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If vacuum boxes are used to securely hold the tissue web to the transfer belt, then web stability is improved, but device complexity and safety hazards increase
Solution Approach 1:
The patent removes the vacuum box system from the transfer belt assembly, extracting the problematic vacuum generation and dust removal subsystems while retaining the essential web holding function through a simplified belt design without permeable sections or vacuum connections
Solution Approach 2:
The patent eliminates the complex, maintenance-intensive vacuum box system in favor of a simpler transfer belt design that does not require vacuum maintenance, dust removal systems, or frequent gleanings, thereby reducing operational complexity and safety hazards
2Stability of the object's composition
If vacuum boxes are used to control tissue web, then web control is improved, but reliability decreases due to plugging and fire hazards
Solution Approach 1:
The patent extracts the vacuum box components that are prone to plugging and fire hazards, replacing them with a non-vacuum based web control system that uses the transfer belt's inherent properties to hold and control the tissue web without creating fire risks or plugging issues
Solution Approach 2:
The patent replaces the unreliable vacuum box system with a simpler, maintenance-free transfer belt design that does not require vacuum maintenance or dust removal systems, thereby improving operational reliability and eliminating fire and explosion hazards
3Productivity
If transfer belt speed is increased to improve productivity, then web handling becomes problematic
Solution Approach 1:
The patent modifies the transfer belt's physical parameters by removing permeable sections and vacuum connections, creating a non-compressive belt design that maintains web stability through friction and geometric constraints rather than vacuum suction, allowing high-speed operation without web wandering
4Stability of the object's composition
If vacuum boxes are used along the entire length of the transfer belt, then web control is improved, but device complexity increases
Solution Approach 1:
The patent removes the vacuum box system entirely from the transfer belt assembly, eliminating the need for vacuum generation, dust removal, and frequent maintenance systems, thereby reducing device complexity while maintaining web control through the simplified belt design
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 approach results in the production of uniformly stable and dimensionally consistent parent rolls, allowing for high-speed winding of soft, high-bulk tissue webs with reduced defects and increased efficiency, avoiding the limitations of vacuum boxes and enhancing web handling.
Implementation Method 1
A displacement sensor measures the amount of deflection of the flexible belt. The amount of deflection is related to the pressure at the nip point
Implementation Method 2
at least one static measurement probe measuring the charge of at least of the endless flexible belt and the web
Implementation Method 3
at least one static induction device for inducing a static charge into at least one of the endless flexible belt and the web
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
An apparatus and method for winding a roll is disclosed. The apparatus engages a reel spool against an endless flexible belt spanning two rolls to form an unsupported span of the belt. The tissue web is carried to the free span on the endless flexible belt, and the reel spool is pushed into the endless flexible belt in the free span winding the roll. A displacement sensor measures the deflection of the endless flexible belt during winding, and, in response, the reel spool position is changed to control the deflection at a desired level. Located within the apparatus are at least one static measurement probe, and at least one static induction device. The probe and the static induction device are used to measure and control the static charge of the tissue web, the transfer belt, or both. By maintaining a predetermined static charge differential between the transfer belt and the tissue web, the reel will have improved web handling and/or transfer efficiency.