Winding Machine Brush Element for Roll Ejection Tension Control
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Solution Overview
Problem
Winding machines produce loose and/or axially offset paper layers in the outer layers of wound rolls due to loss of web tension, leading to waste and quality issues, especially at higher machine speeds and larger roll diameters.
Innovation Solution
Applying at least one brush element to the edge regions of the wound roll during its ejection into the end position, providing an active surface that maintains tension and minimizes loose layers, while also preventing damage and ensuring high-quality output.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the winding machine operates at higher machine speeds and produces larger diameter rolls, then productivity increases, but web tension is lost and winding hardness deteriorates leading to loose and axially offset layers
Solution Approach 1:
The braking action is applied preliminarily during the ejection phase before the winding roll is fully removed from the carrier drum. This preliminary braking maintains web tension in the outer layers during the critical transition period when the roll is most susceptible to loosening, preventing the formation of loose and axially offset layers that would otherwise occur at high operating speeds
2Ease of operation
If the winding roll is ejected into end position with simultaneous or time-staggered braking, then the winding roll can be removed for further processing, but web tension is lost causing loose outer layers
Solution Approach 1:
The braking is applied as a preliminary action during the ejection process itself, before the winding roll is completely removed from the carrier drum. This timing ensures that the outer layers remain under tension throughout the ejection and initial removal phase, preventing layer misalignment while still allowing easy ejection into the end position for subsequent processing
Solution Approach 2:
The braking mechanism provides a cushioning effect by gradually reducing the speed of the winding roll during ejection rather than allowing sudden stops. This controlled deceleration maintains web tension and prevents the formation of loose layers that would occur with abrupt braking, ensuring layer alignment is preserved throughout the ejection process
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 brush element effectively suppresses the formation of loose and/or axially offset paper layers, maintaining quality parameters and reducing waste, allowing for high-quality products to be processed further.
Implementation Method 1
at least one brush element (13) is provided, which can be placed against the produced winding roll (6) in at least one edge area R, at least while it is being ejected into its end position E
Data Source
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Figure 3
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AI summary
The invention relates to a method for winding a moving material web (4), in particular a fibrous web, according to which the material web (4) is wound on successive winding cores (10, 11) to form wound rolls (6). According to the invention, the material web (4) is preferably guided over a peripheral region of a preferably displaceable carrier drum (2) that forms a winding nip (7) with a roll to be wound (6) and is subsequently wound on a winding core (10) to form a wound roll (6). A new winding core (11) is brought into contact with the carrier drum, preferably immediately before a predetermined wound roll diameter (D) is reached in the peripheral region of the carrier drum (2) that is looped by the material web (4), forming a new winding nip (7.1) and the material web (4) is cut after the formation of the new winding nip (7.1) between the new winding core (11) and the carrier drum (2) using at least one separation device (12) and is then transferred to the new winding core (11) and wound on said core. The produced wound roll (6) is ejected into an end position (E) when the winding nip (7) is opened. The method according to the invention is characterised in that at least one respective brush element (13) is brought into contact with at least one edge region (R) and preferably both edge regions (R) of the produced wound roll (6), at least during the ejection into the end position (E). The invention also relates to a winding machine (1) for carrying out said method.