Web Material Storage Device with Movable Trolley for Continuous Winding
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Solution Overview
Problem
Existing plants for winding reels of web-like material face issues such as the need to stop or slow down the feeding process for reel unloading and insertion, which leads to inefficiencies and potential damage to the material, especially with non-woven fabrics, due to the requirement for manual intervention and the mechanical stress on transmission rollers.
Innovation Solution
A storage device with a movable trolley and pneumatic actuator system that allows continuous feeding by storing the web-like material during reel removal and insertion, using a zigzag path with transmission rollers and a flexible elongated element to maintain tension and prevent material stretching, while minimizing operator intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the feeding of web-like material is stopped or slowed for reel unloading and insertion, then the reel removal and insertion operations can be performed, but the productivity of the plant decreases and the operation time increases
Solution Approach 1:
The storage device accumulates web-like material in advance during normal operation, creating a buffer stock that allows reel unloading and insertion operations to proceed without interrupting the feeding process. The material is stored on the movable trolley before it is needed, enabling continuous operation.
Solution Approach 2:
The storage device acts as an intermediary buffer between the winding zone and the feeding zone. It decouples these two operations, allowing the winding zone to perform reel changes while the feeding zone continues to receive material from the storage device, thus eliminating the need for complete stoppage.
2Ease of operation
If transmission rollers are used to move web-like material, then the material can be transported through the storage device, but the rollers may stretch or damage the material especially with non-woven fabrics
Solution Approach 1:
A pneumatic conveyor system is used to transport the web-like material through the storage device. Air flow moves the material gently without mechanical contact that would cause stretching or damage, particularly protecting delicate non-woven fabrics from roller-induced deformation.
Solution Approach 2:
The mechanical transmission roller system is replaced with a pneumatic transport system. Instead of using rollers that physically grip and move the material (causing friction and potential stretching), air pressure and flow are used to convey the material smoothly through the storage device.
3Productivity
If a movable trolley is used to store material, then continuous feeding is enabled during reel operations, but the device complexity increases
Solution Approach 1:
The movable trolley is equipped with its own pneumatic actuation system that can autonomously move between the loading position (near the winding zone) and the feeding position (near the material source). This self-service capability reduces the need for complex external control mechanisms and manual intervention.
Solution Approach 2:
The storage device incorporates a movable trolley that can dynamically change its position along the material path. This dynamic configuration allows the system to adapt between storing material near the winding zone during reel changes and positioning it near the feeding zone during normal operation, optimizing continuous feed capability.
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 quick and efficient reel removal and insertion without stopping the material feed, preventing material damage and reducing the need for manual labor, resulting in increased productivity and reduced operational complexity.
Implementation Method 1
a movable trolley (7) slidably connected to said support structure (2) and movable between a work configuration, in which said movable trolley (7) itself is placed in proximity to said base (3), and a storage configuration, in which said movable trolley (7) is placed in proximity to said support frame (4)
Data Source
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AI summary
Storage device for a plant for winding reels of web-like material, which comprises a support structure (2), a movable trolley (7) slidably connected to the support structure (2) and movable between a work configuration, in which it is placed in proximity to a base (3) of the support structure (2), and a storage configuration, in which it is elevated with respect to the base (3), a first series (5) of first transmission rollers (6) rotatably mounted on the support structure (2) at said base (3), a second series (8) of second transmission rollers (9) rotatably mounted on the movable trolley (7), a plurality of transmission pulleys (11) rotatably mounted on a support frame (4) of the support structure (2), movement means (12) for rotating the first transmission rollers (6) and the second transmission rollers (9), comprising at least one elongated flexible element (13) closed as a ring and at least partially wound around the first transmission rollers (6) and around the second transmission rollers (9) and around said plurality of transmission pulleys (11), at least one motor (10) mechanically fixed to the support structure (2) and fit to a drive pulley (14) at least partially enclosed by the elongated flexible element (13) in order to move each single roller of the first transmission rollers and the second transmission rollers (6, 9).