Web Unwind Stand Automated Roll Handling
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Solution Overview
Problem
Current manufacturing processes for disposable absorbent articles like diapers and catamenial devices face challenges in maintaining continuous web material supply without manual intervention, leading to increased operational efforts, space requirements, and safety concerns due to the need for manual handling and limited automation solutions.
Innovation Solution
A web unwind stand with a positionable roll grasping apparatus and splicing means that enables continuous unwinding and splicing of convolutely wound rolls, allowing for automated loading, unloading, and unwinding of web materials, reducing manual effort and floor space requirements while maintaining constant velocity and tension.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual operation is used for material handling and delivery, then operational flexibility is maintained, but operational effort and safety risks increase
Solution Approach 1:
The patent replaces manual mechanical handling operations with an automated robot system that uses vision guidance and automated splicing mechanisms. The robot performs material delivery, roll loading, and web splicing tasks that were previously done manually, thereby eliminating safety risks associated with manual operation while maintaining operational flexibility through programmable control.
Solution Approach 2:
The system implements self-service capabilities through automated splicing mechanisms that can join web materials without human intervention. The robot system autonomously performs material handling, positioning, and splicing tasks, allowing the manufacturing line to continue operating with minimal human involvement and reduced safety risks.
2Object-affected harmful factors
If additional automation equipment is added to eliminate manual handling, then safety improves, but floor space requirements increase
Solution Approach 1:
The patent merges multiple functions (material handling, roll loading, web splicing, and delivery) into a single integrated robot system. This consolidation eliminates the need for separate automation equipment for each task, reducing overall floor space requirements while maintaining safety improvements through automation.
Solution Approach 2:
The robot system is designed with multi-functionality, capable of performing various tasks including material delivery, roll loading, web splicing, and positioning. This universal system replaces multiple specialized equipment pieces, optimizing floor space usage while providing comprehensive automation for safety improvement.
3Productivity
If current unwind stand configurations are used, then existing manufacturing operations are maintained, but floor space availability for expanded production is limited
Solution Approach 1:
The patent transitions from traditional horizontal floor-space-based unwind stand configurations to a vertical robot system architecture. The robot operates in three-dimensional space, utilizing vertical movement and aerial positioning for material handling and splicing operations. This dimensional change dramatically reduces floor space requirements while maintaining or increasing manufacturing capacity.
Data Source
AI summary
A web unwind stand for obtaining, loading, splicing, and unwinding a web material from a plurality of convolutely wound rolls and forwarding the web material unwound from each of the convolutely wound rolls uninterruptedly to a downstream apparatus is disclosed. The unwind stand has a frame, a positionable roll grasping apparatus having a mandrel connectively engaged thereto and, splicing means. The positionable roll grasping apparatus is capable of obtaining and disposing the convolutely wound rolls proximate to the splicing means relative to the frame.