Turret Unwinder Roll Alignment for Accurate Sheet Splicing
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Solution Overview
Problem
Conventional sheet splicing methods for EVA sheets in solar modules are inefficient and prone to misalignment and meandering, leading to product defects due to manual operations and inaccurate alignment of rolls, especially with the introduction of autonomous mobile robots.
Innovation Solution
A sheet supply apparatus and method using a turret unwinder with fixation chucks, detectors, and a controller to align and correct the position of standby rolls, ensuring accurate splicing by detecting and adjusting the axial ends of rolls and correcting meandering through servomotors and edge profile sensors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual operation is used to apply double-sided tape and move the standby roll for splicing, then the splicing process can be completed, but work time increases and two sheets are not accurately spliced to each other
Solution Approach 1:
The system uses an auto-splicer that automatically performs the splicing operation without manual intervention. The detector detects the positions of both rolls, the corrector automatically adjusts the standby roll position, and the splicer applies tape and bonds the sheets automatically, making the system self-sufficient and eliminating manual operations.
Solution Approach 2:
The patent replaces manual mechanical operations with an automated mechanical splicing system. The auto-splicer uses mechanical components including a detector for position sensing, a corrector for automatic roll positioning, and a bonding mechanism that automatically applies tape and secures the sheets, substituting human labor with automated machinery.
2Productivity
If the second supply roll is not accurately aligned with the first supply roll, then the splicing process can proceed, but material shifting occurs at the splicing region due to misalignment
Solution Approach 1:
Before the actual splicing operation, the detector detects the positions of both the working roll and standby roll, and the corrector performs preliminary alignment adjustment of the standby roll. This preliminary positioning action ensures that when splicing occurs, the sheets are already aligned correctly, preventing material shifting during the bonding process.
Solution Approach 2:
The detector continuously monitors the positions of both rolls and provides feedback to the corrector. Based on this feedback, the corrector automatically adjusts the standby roll position to maintain precise alignment with the working roll, creating a closed-loop control system that ensures continuous accurate splicing.
3Productivity
If the sheet is wound in an inclined state and then meanders during unwinding, then the sheet can be supplied continuously, but the sheet is cut in an inclined state resulting in product defects
Solution Approach 1:
The patent replaces manual alignment methods with an automated detection and correction system. The detector identifies the meandering and inclined state of the sheet, and the corrector automatically adjusts the standby roll position to compensate for these deviations, ensuring the sheet is cut and aligned correctly even when wound and unwound in inclined states.
Data Source
AI summary
Described herein is a sheet supply apparatus for continuously supplying sheets while splicing the leading edge of the sheet of a standby roll to the trailing end of a sheet being unwound from a working roll by using an auto splicer, the sheet supply apparatus including: a turret unwinder provided with fixation chucks that each fix both ends of a paper tube, and configured to switch the positions of the standby and working rolls; a detector configured to detect the position of one of both axial ends of the standby roll; a corrector configured to be connected to each of the fixation chucks and to correct the position of the standby roll; and a controller configured to align an end of the standby roll so that the end of the standby roll is aligned with the end of the working roll while correcting the position of the standby roll.