Variable Diameter Processing Roll for Multi-Length Sheet Conversion
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Solution Overview
Problem
Current web material converting machines are limited to producing only a single distinct panel length and cannot easily switch to produce different sheet lengths, requiring multiple sets of processing rolls and altering the web path, which is inefficient and impractical.
Innovation Solution
The machine incorporates a cutting arrangement with an excess material receiving component, such as a ditch, that can accommodate different extents of material to form sheets of varying lengths, using a vacuum port to hold the material in place, allowing sheets of different lengths to be processed using the same set of processing rolls.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a machine is configured to make a single distinct panel length, then the machine can produce consistent sheet lengths that are multiples of that panel length, but the machine cannot quickly change to produce different panel lengths requiring multiple sets of processing rolls
Solution Approach 1:
The processing roll is made dynamically adjustable through variable diameter sections that can be selectively engaged. The roll includes a first diameter section and a second diameter section, allowing the effective rolling diameter to change based on the desired panel length. This dynamic adjustment enables the machine to produce different panel lengths without requiring multiple fixed processing roll sets.
Solution Approach 2:
The invention changes the physical parameter of the processing roll diameter to accommodate different panel lengths. By providing processing rolls with different diameter sections (first diameter section and second diameter section), the system can switch between parameters to produce various panel lengths while using the same physical roll structure, thereby avoiding the need for multiple complete roll sets.
2Adaptability or versatility
If multiple sets of processing rolls are used to achieve multiple panel lengths, then different panel lengths can be produced, but the machine requires altering the web path and exchanging roll sets which reduces efficiency
Solution Approach 1:
A single processing roll is designed to perform multiple functions by incorporating variable diameter sections. The same processing roll can produce different panel lengths by engaging different diameter sections, eliminating the need for multiple specialized roll sets and the associated web path alterations and roll exchanges, thus maintaining high productivity while achieving versatility.
Solution Approach 2:
The invention merges multiple roll functions into a single processing roll structure. Instead of having separate first processing rolls and second processing rolls for different panel lengths, both functions are combined into one roll with variable diameter sections, allowing seamless transition between different production modes without stopping the web path.
3Manufacturing precision
If the outer circumference of processing rolls is fixed to a multiple of panel lengths, then consistent sheet lengths can be produced, but the machine cannot accommodate different panel lengths without changing rolls
Solution Approach 1:
The processing roll transitions from a fixed circumference design to a dynamic, variable diameter design. The roll includes selectable diameter sections that can be engaged based on the desired panel length, allowing the effective circumference to change while maintaining the precision required for consistent sheet length production. This dynamic adjustment preserves manufacturing precision while enabling adaptability.
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
Enables the production of sheets of different lengths using the same processing rolls, increasing flexibility and efficiency without the need for multiple roll sets or significant adjustments, allowing for seamless transitions between different panel lengths.
Implementation Method 1
The roll has an excess material receiving component having a first mode and a second mode. In the first mode, a first extent of material is accommodated by the excess material receiving component to form sheets of a first length. In the second mode, a second extent of material is accommodated by the excess material receiving component to form sheets of a second length.
Data Source
Figure 1
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AI summary
Apparatuses and methods of forming sheets having different lengths are provided. The apparatuses and methods may also be used to form panel lengths of different values using a same processing roll. In some embodiments, the diameter of the roll need not change. In some embodiments, the spacing between adjacent rolls need not be changed when transitioning from one sheet length to another sheet length. In some embodiments, the processing roll includes an excess material receiving component that can be active or deactivated to switch between different sheet sizes.