Web Reel Change Device with Speed Synchronization
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Solution Overview
Problem
Existing methods for unwinding material webs in processing machines often disrupt operations during roll changes, leading to inefficiencies and potential material thickness issues due to overlapping webs, which can cause disruptions and require costly buffer systems.
Innovation Solution
A device and method that synchronizes the transport speed of the trailing end and new material web, connects them using a connecting element like adhesive tape, and maintains continuous operation by avoiding overlap, utilizing a transport device with integrated separating and holding mechanisms to ensure seamless integration without buffers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the material web is transported at high speed during roll change, then productivity is improved, but the risk of overlap and material thickness issues increases
Solution Approach 1:
The transport device is pre-positioned in the guide area before the roll change begins. The control device pre-synchronizes the transport speed with the reel speed and pre-positions the transport device to receive the trailing end of the material web immediately when it becomes available, eliminating delays and preventing overlap during high-speed operation
Solution Approach 2:
The control device continuously monitors the position of the trailing end and beginning of material web, and dynamically adjusts the transport device position and speed in real-time. This feedback mechanism ensures precise alignment even at high transport speeds, preventing overlap while maintaining productivity
2Manufacturing precision
If a buffer system is used to enable roll change at standstill, then manufacturing precision is improved, but device complexity and cost increase
Solution Approach 1:
The buffer system is completely removed from the unwinding device. Instead, the transport device is integrated directly into the guide area where material webs are connected. This extraction eliminates the need for complex buffer mechanisms while maintaining the ability to connect material webs accurately during continuous operation
Solution Approach 2:
The transport device is merged with the guide area structure, combining the functions of material web guidance, positioning, and connection in a single integrated component. This eliminates the need for separate buffer systems and reduces overall device complexity while maintaining connection precision
3Device complexity
If the transport device is integrated into the guide area, then device complexity is reduced, but the ability to handle high-speed connections is worsened
Solution Approach 1:
The transport device is designed with dynamic positioning capability, allowing it to move along the guide area to precisely intercept the trailing end of the material web at high speed. The transport speed and position are dynamically adjusted by the control device to match the reel speed and material web tension, enabling high-speed connections without complex buffer systems
Solution Approach 2:
The transport device operates continuously during the roll change process, maintaining material web transport without interruption. The integrated design in the guide area allows the transport device to seamlessly receive the trailing end, connect it to the new reel, and continue transport without stopping or requiring buffer intervention, maintaining high speed throughout the connection process
4Manufacturing precision
If overlapping material webs are prevented by precise positioning, then manufacturing precision is improved, but the ease of operation is worsened
Solution Approach 1:
The control device automatically performs all positioning and synchronization operations without manual intervention. The transport device self-adjusts its position and speed to precisely intercept and connect the material web trailing end to the new reel, eliminating the need for operators to manually coordinate complex positioning tasks while maintaining high connection accuracy
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 efficient and trouble-free roll changes with continuous material supply, minimizing material thickness issues and avoiding the need for expensive buffer systems, ensuring consistent web tension and operation stability.
Implementation Method 1
both material webs are connected to one another with a connecting element, for example an adhesive tape can be used as the connecting element
Data Source
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AI summary
The invention relates to a device for changing a reel and for connecting a new material web to the end of an old material web, with a first reel (101) from which the first material web thereof which is wound thereon can be unwound, a transport device (103), particularly a transport roller, by means of which the first material web can be guided in a guiding region at a transport speed, a second reel (121) with which the new material web can be prepared, a drive device for rotatably driving the second reel, a separating device (142) for cutting through the first material web, by means of which the material web can be cut through in the guiding region or upstream of the guiding region in order to produce a trailing end, and a control and/or regulating device for the mutual adjustment of the trailing end and the beginning (125) of the second material web, such that the trailing end and the beginning of the web are at a distance of more than 0 mm from each other and particularly do not overlap. The trailing end and the beginning of the new material web can be connected to each other in the guiding region of the transport device by means of a connection element, and the transport speed of the trailing end and the beginning of the web corresponds to more than 0 metre per minute in the guiding region.