Continuous Roller Replacement in Web Treatment Systems
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Solution Overview
Problem
The existing methods for replacing treatment rollers in web treatment processes, such as thermally solidifying nonwovens, often disrupt the production process due to the need to interrupt material transport and adjust process parameters, leading to reduced productivity and increased waste.
Innovation Solution
A method where a second roller is introduced to form a secondary processing gap with the counter tool while the first roller is still in operation, allowing continuous web treatment and reducing line forces, enabling the first roller to be shifted to a parking position without interrupting the process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a treatment roller is replaced by stopping the production process and moving the roller to a parking position, then the treatment roller can be replaced, but the productivity decreases due to process interruption
Solution Approach 1:
A second treatment roller is prepared in advance in a parking position adjacent to the first treatment roller. When the first roller needs replacement, the second roller is already positioned and ready to immediately take over the treatment function, eliminating the need to stop the production process for roller replacement preparation.
Solution Approach 2:
The second treatment roller acts as an intermediary element that enables continuous operation. While the first roller is being replaced, the second roller maintains the treatment function, serving as a mediator that bridges the replacement process and ensures uninterrupted web treatment.
2Loss of time
If the treatment roller is replaced quickly by mechanical means, then the replacement time is reduced, but the web transport must be interrupted causing waste
Solution Approach 1:
The system maintains continuous useful action by having the second treatment roller ready in the parking position. When the first roller is replaced, the second roller immediately assumes the treatment function, ensuring that the web transport and treatment process continue without interruption, thus preventing web material waste.
3Force
If the line force in the treatment gap is reduced during roller replacement, then the web tension is minimized, but the treatment effectiveness may be compromised
Solution Approach 1:
The system dynamically adjusts the line force during the roller replacement process. The line force is reduced only when the web passes through the first treatment gap during replacement, while the second treatment gap maintains appropriate treatment forces. This dynamic adjustment minimizes web tension during replacement while ensuring treatment effectiveness is maintained when the second roller is operational.
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
This approach allows for seamless roller replacement without halting the production process, maintaining continuous web treatment and reducing waste, thereby enhancing productivity and efficiency.
Implementation Method 1
An exemplary treatment of a web is the thermal solidification of a web that includes nonwovens that have thermoplastic fibers or filaments
Implementation Method 2
The surface temperature of the heated roller is usually between 80° C and 300° C, preferably between 120° C and 250° C
Implementation Method 3
At least one of the two rollers, preferably the treatment roller, is heated
Implementation Method 4
The line force in the treatment gap in thermobonding processes is usually between 10 - 300 N/mm, preferably 30 - 150 N/mm
Data Source
Figure 1~2b
Figure 3a~3f
Figure 4a~4d
AI summary
The invention relates to a method for the treatment of a product web (W), in which the product web (W) is transported in an advance direction (V) and is guided through a first treatment gap (26) formed by a treatment roll (16') located in a first working position and a counter tool (17), comprising the following steps for the replacement of the first roll: -providing a second roll (16'', 31); -moving the second roll (16'', 31) into a second working position in which the second roll (16'', 31) forms a second treatment gap (30, 32) with the counter tool (17); -moving the first treatment roll (16') into a first parked position in which it does not form a treatment gap with the counter tool (17).