Web Rewinding Evaluation for Defect Localization and Strip Precision
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Solution Overview
Problem
Existing rewinding machines struggle with accurate defect localization and quality control of web materials during the rewinding process, particularly due to changes in dimension and mechanical actions post-winding, leading to suboptimal secondary reels with variable strip width and edge position.
Innovation Solution
A rewinding machine equipped with a cutting device and a web material evaluation system that includes video cameras and other sensors to detect defects and dimensional features of the web material before and after cutting, allowing for precise control of the winding process and adjustment of parameters like tension to ensure consistent reel quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If web material is slit into longitudinal strips and wound into secondary reels, then productivity is improved by producing multiple reels in parallel, but manufacturing precision deteriorates due to variable strip width and edge position
Solution Approach 1:
The system performs preliminary measurement of web material width and position using video cameras and sensors before the cutting and winding operations. This allows the control system to pre-calculate blade positioning and winding parameters to compensate for expected dimensional changes, ensuring consistent strip width and edge position in the final secondary reels
Solution Approach 2:
The system continuously monitors web material dimensions during the slitting and winding process using video cameras and sensors. The control system uses this real-time feedback information to dynamically adjust blade positions and winding parameters, compensating for dimensional variations and maintaining manufacturing precision across all parallel secondary reels
Solution Approach 3:
The system changes operational parameters such as blade positioning, winding tension, and winding speed based on measured web material characteristics. By dynamically adjusting these parameters during the process, the system compensates for dimensional changes in the web material after winding, ensuring consistent strip width and edge position in the produced secondary reels
2Manufacturing precision
If evaluation systems are installed to detect defects and dimensional features, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The video cameras and sensors are designed to perform multiple functions simultaneously: detecting web material width, positioning longitudinal edges, identifying defects, and monitoring dimensional changes. This multi-functionality reduces the need for separate dedicated devices for each measurement task, thereby limiting the increase in device complexity while maintaining high manufacturing precision
Solution Approach 2:
The system combines multiple detection functions (width measurement, edge positioning, defect detection) into a single integrated evaluation system using video cameras and sensors. By merging these functions into one coordinated system rather than using separate independent devices, the overall device complexity is limited while achieving comprehensive quality control
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
The system enables the production of high-quality secondary reels with consistent strip width and flat edges, improving the efficiency and quality of the rewinding process by accurately detecting and correcting defects and dimensional changes in real-time.
Implementation Method 1
at least one video camera (61), arranged in an area of the feeding path (P) between a winding roller (5) and a guide roller (25), downstream of the position where the web material (N) is slit into strips (S1-Sn)
Data Source
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AI summary
The machine (1; 100) comprises a winding station (3; 101), adapted to receive secondary winding cores (T) coaxial with, and adjacent to, one another. A cutting device (11; 104) is also provided, with a plurality of blades (13; 105), arranged upstream of the winding station (3; 101) with respect to the feeding direction of the web material (N) and adapted to subdivide the web material into plurality of strips (S1-S5) of web material; The machine has a web material evaluation system and a programmable unit (71) for processing data collected by the web material evaluation system.