Web Splicing Apparatus for Continuous High-Speed Manufacturing
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Solution Overview
Problem
Conventional splicing techniques in high-speed manufacturing of personal care absorbent articles require temporary halting of the web, causing interruptions in processing, which is undesirable in high-speed environments.
Innovation Solution
An apparatus and method for creating a butt splice between the end of an expiring web and a replacement web without halting the web's advancement, using a controller to detect the trailing end of the traveling web and position the leading end of the replacement web adjacent to it, followed by a web joiner to create a joint, ensuring continuous operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional splicing techniques are used to join the trailing end of an expiring coil to the leading end of a replacement coil, then the webs can be coupled together, but the processing machine must be temporarily halted, causing interruption of production
Solution Approach 1:
The replacement coil is positioned and prepared in advance on a second support surface before the splicing operation begins. The leading end of the replacement web is pre-aligned and ready for immediate joining when the trailing end of the traveling web arrives, eliminating the need to halt the processing machine.
Solution Approach 2:
A splicing assembly with first and second support surfaces acts as an intermediary device between the traveling web and the replacement coil. This intermediate structure allows the splicing operation to occur without disrupting the continuous movement of the web through the processing machine.
2Ease of operation
If the web advancement is halted for manual splicing, then operators can join the webs, but temporary stops occur in the high-speed processing environment
Solution Approach 1:
The splicing assembly is configured to automatically position and join the webs without requiring manual intervention during the critical splicing operation. The controller coordinates the movement and alignment of both webs, and the web joiner automatically creates the bond, eliminating the need for operators to manually splice while the machine is stopped.
Solution Approach 2:
The system maintains continuous web advancement through the processing machine during the entire splicing operation. The controller manages the timing and coordination so that the web joiner operates while the web continues to move, ensuring uninterrupted production flow.
3Productivity
If a butt splice is created between traveling web and replacement web without halting advancement, then processing continuity is maintained, but precise positioning and joining must be achieved dynamically
Solution Approach 1:
The splicing assembly is designed to dynamically adjust and position the webs during movement. The controller actively manages the positioning of both the traveling web and replacement web, allowing precise alignment to be achieved while both webs are in motion, rather than requiring static positioning after halting the machine.
Solution Approach 2:
The controller monitors and coordinates the positions of both webs in real-time, enabling precise alignment to be achieved dynamically during the splicing operation while maintaining continuous web advancement.
Data Source
AI summary
An apparatus for splicing comprises a first web support surface configured to support a traveling web thereon and a second web support surface configured to support a replacement web thereon. The first traveling web travels in a machine direction. The splicing assembly also comprises a first web sensor and a web joiner. A controller is configured to determine, via the first web sensor, a position of a trailing end of the traveling web and to, in response to determining the position of the trailing end, cause a leading end of the replacement web to be positioned adjacently to the trailing end. The computer is also configured to control the web joiner to create a joint coupling the trailing end to the leading end.