Web Reel Defect Tracking for Continuous Unwinding
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Solution Overview
Problem
The existing methods for handling defective web materials during the winding process result in undersized reels, increased setup times, and additional costs due to the need for frequent reel changes during unwinding, as defects are not effectively managed, leading to quality losses and inefficiencies in processing.
Innovation Solution
A monitoring method that detects irregularities in the web material during the winding process, correlates them with running parameters, and provides this information for the unwinding process, allowing for accurate positioning and handling of defects, thereby enabling the continued use of defective reels and reducing material waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the winding process is stopped and a new reel sleeve is mounted when a defect is detected, then the defect is removed from the process, but the reel becomes undersized and carries less web material
Solution Approach 1:
The patent applies preliminary action by marking the defect position and storing its data during the winding process, before the unwinding process begins. This allows the unwinding process to proactively prepare for the defect by positioning the take-up roller to bridge over the defect area, preventing the need to stop and discard the reel, thus maintaining full web material capacity
Solution Approach 2:
The patent introduces an intermediary element - a marking indicator (such as a visible mark or RFID tag) placed at the defect location on the reel. This intermediary allows the unwinding system to detect and respond to the defect position without physically removing or discarding the defective web material, enabling continuous processing and full reel utilization
2Adaptability or versatility
If the winding device is modified to handle defects, then defect handling capability is improved, but the device complexity increases
Solution Approach 1:
The patent replaces complex mechanical modifications to the winding device with a simpler detection and data storage system. Instead of adding mechanical mechanisms to physically handle defects during winding, the system uses sensors to detect defects, stores their positions, and transfers this information to the unwinding process, significantly reducing winding device complexity while maintaining adaptability
Solution Approach 2:
The patent extracts the defect handling function from the winding device itself and relocates it to the unwinding process. By removing defective sections during unwinding rather than during winding, the winding device remains simple while the system gains defect handling capability through the unwinding system's existing mechanical capabilities
3Reliability
If undersized reels are produced, then defects are removed early, but additional setup times occur during unwinding due to frequent reel changes
Solution Approach 1:
The patent implements feedback by continuously monitoring the web material during winding, detecting defects, and recording their positions. This feedback loop allows the system to provide defect location information to the unwinding process, enabling proactive defect management that prevents unexpected reel changes and reduces setup time
Solution Approach 2:
The system performs preliminary action by pre-marking and recording all defect positions during winding before the reel is sent to unwinding. This advance preparation allows the unwinding process to smoothly navigate around defects without stopping or changing reels, eliminating frequent setup times and maintaining continuous operation
Data Source
AI summary
The invention relates to a monitoring method (100) for monitoring a winding process on a winding device (1), comprising: providing (104) a correlation of an irregularity (12) of a web material (11) to a running parameter (13) of the reel (10) for an unwinding process. The invention further relates to a control method (200) for performing an unwinding process on an unwinding device, comprising: obtaining (201) a correlation of an irregularity (12) of a web material (11) to at least one running parameter (13) of a reel (10) from a winding process. Furthermore, the invention relates to a processing method (300) for performing a process of processing a web material (11). Furthermore, the invention relates to a winding device (1) for performing a winding process of a web material (11) to a reel (10), an unwinding device (2) for performing an unwinding process of a web material (11) of a reel (10) and a processing system (3) for processing a web material (11).