Automatic Web Splicing System for Continuous Roll Changeover
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Solution Overview
Problem
Current web splicing methods in paper and plastic laminate manufacturing are inefficient, requiring manual intervention or machine slowdowns, leading to potential printing registration errors and thickness variations that affect coating or printing results, and lack an automated solution for continuous web supply.
Innovation Solution
An automatic web splicing system with receiving and delivering platforms, adjustable clamping means, shearing blades, and adhesive tape dispensers that allow for precise alignment and simultaneous application of adhesive tape from both sides, enabling continuous web supply without machine stoppages.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual splicing is performed, then splicing can be completed, but machine must be stopped or slowed down, reducing productivity
Solution Approach 1:
The splicing system performs alignment, adhesive application, and joining operations automatically without requiring manual intervention. The system self-regulates the splicing process through automated platforms and dispensers, eliminating the need to stop or slow down the machine while maintaining reliable splicing completion
Solution Approach 2:
The patent replaces manual mechanical splicing operations with an automated system comprising adjustable platforms, sensors, adhesive dispensers, and heating elements. This automated mechanical system maintains machine productivity while ensuring reliable splicing through controlled processes
2Reliability
If overlapping splicing method is used, then webs can be joined, but web thickness increases at overlapped portion, affecting coating or printing results
Solution Approach 1:
The splicing process is divided into distinct stages: alignment of web edges, application of adhesive only at the bonding interface, and controlled joining. This segmentation ensures that adhesive is applied precisely where needed without creating overlapping thickness variations that would affect subsequent coating or printing operations
Solution Approach 2:
The adhesive dispenser applies adhesive locally only at the splicing interface rather than over the entire web surface. This localized application ensures that the bonding area receives adequate adhesive while the rest of the web maintains uniform thickness, preventing defects in coating or printing quality
3Ease of operation
If splicing is performed manually, then flexibility is maintained, but splicing accuracy decreases leading to improper printing registration
Solution Approach 1:
The system incorporates sensors that detect web position, alignment, and splicing progress in real-time. This feedback mechanism allows the automated system to maintain high splicing accuracy by continuously monitoring and adjusting the positioning of web edges, ensuring proper printing registration while preserving operational flexibility
Solution Approach 2:
Manual alignment and positioning operations are replaced with automated platforms and sensor-based detection systems. This substitution eliminates human error in measurement and positioning while maintaining the flexibility to handle different web types and splicing requirements through programmable 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 ensures continuous web flow, improves splicing accuracy, reduces manual intervention, and maintains machine uptime by allowing seamless transitions between web rolls, enhancing joint quality and eliminating thickness variations.
Implementation Method 1
The splicing is done by applying adhesive over trailing end or leading end and joining by overlapping the web or by using an adhesive tape to join the two ends
Implementation Method 2
a shearing blade for cutting a trailing edge of a finished running web held between the delivering platform and the receiving platform by clamping means
Implementation Method 3
a clamping means for each platform for clamping the webs during splicing
Implementation Method 4
an adjusting means for moving, adjusting, and maintaining the delivering platform and one of the receiving platforms in-line with each other
Data Source
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AI summary
A system for automatic web splicing, comprises of an unwinding section, a splicing section, an accumulator, and a controller to facilitate clamping, cutting and splicing of the webs to provide continuous web supply to a utilizing machine, the system comprises also at least two receiving platforms, a space defining a splicing area between the delivering platform and the receiving platform, one platform for receiving a running web and other platform for a new web and at least one dispenser so as to splice trailing edge of a running web and a leading edge of a new web with an adhesive tape. The system joins the two webs in completely auto mode and keeps the utilizing machine running continuously without stoppage.