Variable Plunge Speed Saw for Coreless Tissue Rolls
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Solution Overview
Problem
Traditional log saws used for cutting coreless tissue rolls often damage the innermost plies of tissue paper and collapse the roll due to constant high plunge speed, leading to poor product quality and increased waste.
Innovation Solution
A method and system that regulate the plunge speed of the saw blade by defining a core offset value, allowing the plunge speed to change from a first speed to a second speed when reaching the core, minimizing roll crush and tissue damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If constant high plunge speed is used during cutting, then throughput rate is maintained, but the innermost plies of tissue paper are damaged and the roll collapses
Solution Approach 1:
The patent applies dynamics by making the plunge speed variable rather than constant. The saw blade operates at different plunge speeds during different phases of the cutting cycle: higher speed during indexing and outer ply cutting, and reduced speed when cutting the innermost plies near the core. This dynamic speed adjustment maintains overall throughput while preventing damage to sensitive tissue layers and roll collapse.
2Productivity
If high plunge speed is maintained throughout the cut, then cutting efficiency is improved, but saw blade life is reduced
Solution Approach 1:
The patent implements periodic action by cycling the plunge speed between higher and lower values during the cutting operation. The saw operates at elevated plunge speeds during non-critical cutting phases (indexing and outer plies) and reduces speed during critical phases (innermost plies), creating a periodic speed pattern that extends blade life while maintaining acceptable cutting efficiency.
3Device complexity
If constant plunge speed is used, then the cutting process is simple, but the center aperture becomes non-circular or collapsed
Solution Approach 1:
The patent uses dynamic plunge speed adjustment to preserve the circular shape of the center aperture. By reducing plunge speed when the saw approaches and cuts the innermost plies near the core, the system prevents excessive force that would deform the aperture. This dynamic control achieves accurate circular aperture formation without requiring complex additional hardware.
Data Source
AI summary
The present disclosure is directed to a method for cutting a coreless rolled paper product. The method includes defining a core offset value for a cut, the cut having a starting point and an ending point, setting a plunge speed for a saw to a first plunge speed, and changing the plunge speed to a second plunge speed when the saw reaches the core offset value.