Unwind Apparatus for Convolutely Wound Web Rolls
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Solution Overview
Problem
Current manufacturing processes for disposable absorbent articles like diapers and catamenial devices face challenges in continuously supplying convolutely wound web materials to web consuming apparatuses, as conventional multi-axis robots with end effector mechanisms are not designed to handle such materials effectively, leading to manual operation inefficiencies and space constraints.
Innovation Solution
A multi-axis robot with a unique end effector mechanism featuring a stationary motor, rotational coupling, and a mandrel capable of releasably engaging convolutely wound rolls, allowing for uninterrupted unwinding and splicing of web materials, thereby automating the loading and unloading process and maintaining the leading edge orientation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If conventional multi-axis robots with end effector mechanisms are used, then automation is achieved, but they cannot effectively grip convolutely wound web materials
Solution Approach 1:
The end effector is segmented into multiple functional components: a mandrel for central engagement, compression fingers for radial compression, and a compression arm mechanism. This segmentation allows each component to perform a specific function necessary for handling soft convolutely wound materials that conventional grippers cannot handle.
Solution Approach 2:
The mandrel acts as an intermediary element that inserts into the hollow core of the convolutely wound roll, providing a stable central anchor point. This intermediary enables reliable gripping of soft web materials by transferring force through the core rather than relying on external compression alone.
2Ease of operation
If manual operation is used for material handling, then flexibility is maintained, but labor effort and floor space requirements increase
Solution Approach 1:
The end effector mechanism is designed with universal applicability to handle different sizes and types of convolutely wound rolls through adjustable compression forces and mandrel dimensions. This multi-functionality maintains operational flexibility while eliminating the need for multiple specialized devices and reducing floor space requirements.
Solution Approach 2:
The system transitions from two-dimensional planar robot motion to three-dimensional spatial manipulation by incorporating vertical mandrel insertion and radial compression movements. This dimensional expansion enables automated handling of volumetric roll structures while maintaining precision and flexibility.
3Productivity
If continuous web supply is required, then manufacturing speed is maintained, but uninterrupted splicing becomes challenging
Solution Approach 1:
The system performs preliminary actions by maintaining a ready supply of pre-positioned convolutely wound rolls and pre-coordinating splicing operations. The robot system prepares the next roll and positioning operations in advance, ensuring seamless transitions and uninterrupted web supply to maintain manufacturing speed.
Solution Approach 2:
The end effector enables continuous operation by facilitating rapid roll changes and splicing operations without stopping the web feed. The mechanism maintains continuous useful action through coordinated robot movements that perform mandrel extraction, roll replacement, and splicing preparation without interrupting the manufacturing process.
Data Source
AI summary
An unwind apparatus for obtaining, loading, splicing, and unwinding convolutely wound rolls of web material and forwarding the web material unwound from each of the convolutely wound rolls uninterruptedly to a downstream apparatus is disclosed. The unwind apparatus provides for a multi-axis robot and an end effector operatively connected to the multi-axis robot. The end effector provides for a stationary motor, a rotational coupling mechanically coupled to the stationary motor, and, a mandrel mechanically coupled to the rotational coupling. The mandrel is capable of releasably engaging the convolutley wound rolls of web material.