Supply Roll Stand for Continuous Payout and Core Transfer
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Solution Overview
Problem
Production lines experience significant downtime due to the process of replacing depleted supply rolls, which involves removing cores and loading new rolls, leading to inefficiencies and potential safety hazards.
Innovation Solution
A supply roll stand with a lift support, unwind assembly, and transfer support that allows continuous unwinding of one roll while another is loaded, minimizing downtime by transferring cores and enabling seamless roll changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a supply roll is replaced after depletion, then the material supply is maintained, but production time is lost during the changeover process
Solution Approach 1:
The system performs preliminary actions by loading the next supply roll onto the lift support while the current roll is still being used. The transfer support is positioned and ready to receive the core before the current roll is completely depleted, enabling seamless transition without production interruption.
Solution Approach 2:
The transfer support acts as an intermediary mechanism between the lift support and the unwind assembly. It receives the core from the lift support and facilitates its removal while simultaneously preparing to receive the next core, enabling continuous operation without direct manual intervention during roll changes.
2Ease of manufacture
If manual roll changing is performed, then roll replacement is achieved, but labor intensity and safety risks increase
Solution Approach 1:
The system performs self-service through automated mechanisms. The lift support automatically raises and lowers rolls, the transfer support automatically receives and removes cores, and the unwind assembly automatically tensions and pays out material. This eliminates manual labor and associated safety risks while maintaining roll replacement capability.
Solution Approach 2:
Manual mechanical operations are replaced with an automated mechanical system comprising motors, actuators, and controlled mechanisms. The lift support uses a motor-driven mechanism to raise/lower rolls, while the transfer support uses an actuator to move cores, replacing manual handling with automated mechanical systems.
3Device complexity
If the supply roll stand structure is simplified, then device complexity is reduced, but roll changing efficiency decreases
Solution Approach 1:
The supply roll stand is segmented into distinct functional modules: the lift support for vertical roll movement, the transfer support for core handling, and the unwind assembly for material payout. Each module operates independently with its own actuator, allowing simplified individual components that work together to achieve high roll changing efficiency.
Solution Approach 2:
The lift support and transfer support serve multiple functions. The lift support not only raises rolls for unwinding but also positions them for transfer to the transfer support. The transfer support both receives cores from the lift support and facilitates their removal, enabling a single structure to perform multiple operations that increase productivity.
Data Source
AI summary
A supply roll stand for loading first and second supply rolls each including a core and dispensing material therefrom. The supply roll stand broadly comprises a frame, a lift support, an unwind assembly, and a transfer support. The lift support receives the first supply roll and raises the first supply roll. The unwind assembly unwinds the first supply roll as the lift support raises the first supply roll. The transfer support receives the first supply roll so that the first supply roll is transferred from the lift support. The lift support receives the second supply roll after the first supply roll is transferred to the transfer support. The transfer support dispatches the core of the first supply roll when the first supply roll is depleted of material. The unwind assembly unwinds the second supply roll when the first supply roll is depleted of material.