Wearable Article Manufacturing: Variable Pad Speed for Larger Spacing
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Solution Overview
Problem
Existing manufacturing methods for wearing items face challenges in increasing the distance between neighboring workpieces without enlarging the rotary drum diameter, due to constant feeding and rotation speeds leading to short acceleration zones.
Innovation Solution
A method and device that adjust the feeding speed of a workpiece continuous body in response to non-constant rotation speeds of pads, allowing equal relative speeds during holding and non-constant speeds in specific zones to expand the distance between workpieces without increasing the drum diameter.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If the zone of constant rotation speed of pads is made long, then the acceleration zone becomes short, but the distance between neighboring workpieces cannot be sufficiently increased and the drum diameter becomes large
Solution Approach 1:
The invention applies dynamics by making the rotation speed of pads variable rather than constant. The workpiece conveying device changes the rotation speed of pads during operation, specifically adjusting the circumferential speed at different zones (acceleration zone, constant speed zone, deceleration zone) to optimize workpiece spacing without increasing drum diameter. This dynamic speed adjustment allows sufficient acceleration distance within a compact drum structure.
Solution Approach 2:
The invention changes the parameter of rotation speed from constant to variable. By adjusting the circumferential speed parameter of pads in different operational zones, the system achieves optimal workpiece spacing. The feeder also adjusts the feeding speed parameter to match the variable pad speed, ensuring synchronized operation and preventing tension while achieving larger pitches between workpieces within a standard drum diameter.
2Ease of operation
If the pads rotate at constant speed, then the feeding process is simple, but the acceleration zone becomes short and workpiece spacing is insufficient
Solution Approach 1:
The system transitions from constant speed operation to variable speed operation. The workpiece conveying device incorporates speed adjustment capability that modifies pad rotation speed during different zones of rotation. This dynamic control extends the effective acceleration zone length without complicating the overall feeding process, as the speed changes are automatically managed by the control system.
Solution Approach 2:
The rotation speed parameter of pads is changed from a fixed constant value to a variable parameter that changes according to the operational zone. The system defines different speed profiles for acceleration, constant speed, and deceleration zones, allowing sufficient acceleration distance while maintaining operational simplicity through automated parameter management.
3Device complexity
If the feeder feeds at constant speed, then the feeding mechanism is simple, but it cannot synchronize with variable pad speeds to prevent tension
Solution Approach 1:
The feeder incorporates feedback control that responds to the variable rotation speed of pads. The feeding speed is adjusted based on the actual pad speed, creating a closed-loop control system. This feedback mechanism ensures synchronized operation between the feeder and pads, preventing workpiece tension and maintaining quality consistency while managing complexity through automated speed matching.
Solution Approach 2:
The feeding speed parameter is changed from constant to variable, matching the pad rotation speed profile. The feeder adjusts its operating parameter in real-time to synchronize with the pads' acceleration, constant speed, and deceleration zones. This parameter synchronization prevents tension and ensures consistent workpiece quality without requiring overly complex mechanical coupling mechanisms.
Data Source
AI summary
A manufacturing method for a wearing item repeatedly executes: a step of, at a preceding pad, receiving and holding a distal end part of a continuous body to convey; a step of, at a following pad, catching up with the preceding pad; a both holding step of, at both of the preceding pad and the following pad, holding the continuous body; and a cutting step of cutting the distal end part of the continuous body to generate an individual workpiece on the preceding pad, and, in the both holding step, relative speeds of both of the pads are equal to each other, and both of the pads rotate at a non constant speed in at least part of a zone, the continuous body is fed from the feeder at the non-constant speed in response to a change in a speed of the pads that rotate at the non-constant speed.