Web Diverter Unit for Transverse Web Alignment During Splicing
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Solution Overview
Problem
The existing systems for splicing transversely wound material rolls in the manufacture of disposable garments face challenges due to the varying transverse position of the running web during unwinding, leading to potential misalignment and splice failures.
Innovation Solution
A web unwinding and splicing system that includes a turret unwind unit, a web splicing unit, and a web diverter unit with a movable web retaining assembly. The web diverter unit temporarily holds the running web at a constant transverse position, ensuring precise alignment with the waiting web for accurate splicing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a transverse wind pattern is used to wind the web on the material roll, then the web can be efficiently wound and stored, but the transverse position of the web varies during unwinding, making alignment difficult
Solution Approach 1:
The system performs preliminary actions by predicting the future transverse position of the running web before splicing occurs. The control system calculates where the web will be at the splicing moment and pre-positions the splicing mechanism accordingly, ensuring accurate alignment despite the varying transverse position during unwinding
Solution Approach 2:
The system uses feedback by continuously monitoring the actual transverse position of the running web and comparing it with the predicted position. The control system adjusts the splicing timing and position based on this feedback to maintain precise alignment between the running web and waiting web
2Extent of automation
If the splicing system times the splicing based on anticipated transverse location, then splicing can be performed automatically, but the anticipated location may be inaccurate, leading to splice failures
Solution Approach 1:
The control system incorporates feedback by continuously monitoring the actual transverse position of the running web and adjusting the splicing operation based on real-time position data. This feedback mechanism corrects deviations from the anticipated position, ensuring reliable splicing while maintaining full automation
Solution Approach 2:
The system applies dynamics by making the splicing operation adaptive rather than static. The control system dynamically adjusts the splicing timing and position based on the actual web movement, transforming a rigid timed operation into a flexible, position-based operation that maintains reliability
Data Source
AI summary
A system and method for the splicing transversely wound webs is provided. A web diverter unit includes a web retaining assembly movable between a first position where the web retaining assembly is not in contact with the running web and a second position where the web retaining assembly is in contact with the running web. With the web retaining assembly in the second position, the web retaining assembly temporarily holds the running web being unwound off of the running web material roll at a constant transverse position to enable precise alignment of the running web with the waiting web for splicing therebetween.