Variable Speed Vacuum Rolls for High-Speed Product Folding
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Solution Overview
Problem
Existing blade folding technologies for products at high speeds suffer from precision and repeatability issues, leading to deformation and damage due to the 'cudgeling effect' and lack of direct positioning control, especially at line speeds ranging from 400 to 4000 products per minute.
Innovation Solution
A folding apparatus comprising a receiving roll, an oscillating member, and a folding roll, utilizing vacuum profiles and actuation to precisely control and fold products, ensuring accurate alignment and reduced force application, thereby maintaining product integrity and precision at high speeds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If blade folding is used to fold products at high speeds, then productivity is improved, but manufacturing precision deteriorates due to timing dependency and lack of direct positioning control
Solution Approach 1:
The patent replaces the mechanical blade striking system with a vacuum-based holding system. Instead of using a blade to strike and fold the product, the invention uses vacuum rolls to hold and manipulate the product through suction, eliminating the need for precise timing and direct mechanical impact while maintaining high-speed operation capability.
Solution Approach 2:
The patent introduces vacuum as an intermediary force between the folding apparatus and the product. The vacuum field acts as a mediator that can hold and position the product without direct mechanical contact, providing precise positioning control while enabling high-speed operation without the cudgeling effect.
2Productivity
If blade folding is used to fold products at high speeds, then productivity is improved, but object-generated harmful factors worsen due to the cudgeling effect causing deformation and damage
Solution Approach 1:
The patent replaces the high-impact mechanical blade striking system with a gentle vacuum-based holding system. The vacuum rolls hold the product through suction forces rather than mechanical impact, completely eliminating the cudgeling effect that causes product deformation and damage while maintaining high-speed folding capability.
Solution Approach 2:
The patent converts the potential harm of high-speed mechanical impact into a beneficial gentle vacuum holding system. Instead of allowing the blade's striking force to damage the product, the invention uses vacuum pressure to gently hold and manipulate the product, turning the high-speed operation from a source of harm into a source of efficiency without deformation.
3Device complexity
If blade folding is used, then device complexity is reduced, but measurement precision deteriorates because the product is not held in place during folding
Solution Approach 1:
The patent introduces vacuum as an intermediary holding mechanism between the folding apparatus and the product. The vacuum rolls provide continuous holding and positioning control throughout the folding process, ensuring the product remains precisely positioned without requiring complex mechanical clamping or timing mechanisms.
Solution Approach 2:
The patent replaces complex mechanical positioning and holding mechanisms with a simpler vacuum-based system. The vacuum rolls provide inherent positioning control through suction, eliminating the need for complex timing mechanisms, clamps, or direct mechanical holding devices while maintaining precise product positioning.
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
The apparatus achieves precise and repeatable folding of products at high speeds with reduced deformation and damage, maintaining accurate control and alignment, and can handle a variety of products including disposable personal care items.
Implementation Method 1
utilizing vacuum profiles and actuation to precisely control and fold products
Data Source
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AI summary
An apparatus for folding a product having a first portion and a second portion has a receiving roll with a drive assembly for rotating the receiving roll at variable surface speeds in a first direction of rotation. The receiving roll is adapted to selectively hold the first and second portions of the product thereto. A folding roll has a drive assembly for rotating the folding roll at variable surface speeds in a second, opposite direction of rotation. The folding roll is adapted to selectively hold the first portion of the product thereto. An oscillating member is adapted to transfer the first portion of the product from the receiving roll to the folding roll. The oscillating member has a drive assembly for moving the oscillating member at variable surface speeds in both the first direction and the second direction.