How can a three-station rewinding machine achieve flexible production through modular design?

The flexible production capacity of the three-station rewinding machine comes from the precise design of its power distribution system. The rotating spindle is connected to the drive motor through a synchronous wheel and a synchronous belt to achieve synchronous rotation of the three stations, while the turntables at both ends of the spindle complete the precise collaboration of unwinding, rewinding, and unloading through independent drive components and sensors. This architecture not only ensures the independent operation of each station, but also realizes the dynamic switching of functions through modular design.

The core of the modular design lies in the segmented rotating seat and linear copper sleeve on the turntable. The segmented rotating seat can be customized according to the diameter of the paper core, and is connected to the turntable through a quick plug-in structure to achieve plug-and-play of paper cores of different specifications; the linear copper sleeve adapts to coils of different widths through a standard interface, and cooperates with an adjustable guide rail to ensure the centering accuracy of the coil during the rewinding process. For example, when it is necessary to switch from processing toilet paper to producing plastic film, only the segmented rotating seat and the linear copper sleeve need to be replaced to complete the equipment changeover within 15 minutes.

To reduce the difficulty of changing models, the equipment adopts a standardized interface design:
Segmented rotating seat: DIN standard positioning pins are used to connect the turntable to ensure repeated positioning accuracy ≤0.05mm;
Linear copper sleeve: fixed by pneumatic chuck and guide rail, supporting a width adjustment range of ±2mm;
Human-machine interaction interface: integrated with the changeover wizard function, the operator can select the target specification through the touch screen, and the system automatically generates a changeover step list.

Application scenarios of modular design: from standard products to customized needs
In the production of medical tapes, different types of tapes require different diameters of paper cores. Traditional equipment needs to be shut down for more than 4 hours for changing models, while the three-station rewinding machine can complete the paper core specification switching within 30 minutes through modular design. For example, when switching from producing 1-inch paper core tape to 2-inch specifications, the operator only needs to:
Press the changeover button, and the system automatically stops the current station;
Remove the old segmented rotating seat and install the new specification seat;
Adjust the width of the linear copper sleeve and calibrate the coil centering;
Start the equipment, and the system automatically compensates for the tension parameters.

The width of plastic film usually ranges from 50mm to 2000mm. Traditional equipment requires the replacement of the entire rewinding shaft, which is costly. The three-station rewinding machine supports dynamic width adjustment of ±50mm through modular linear copper sleeves. For example, when the order switches from 800mm wide packaging film to 1200mm specifications, the operator only needs to loosen the copper sleeve fixing bolts, slide the guide rail to the target position, and the system automatically calibrates the tension sensor to resume production.

For special materials such as coated white paper and aluminum foil, customers often require customized roll diameter and end surface effects. The three-station rewinding machine can achieve the following through the customized design of the segmented rotating seat:
Multi-level roll diameter control: According to customer requirements, the segmented rotating seat can preset 3-5 roll diameter gears;
End surface embossing function: The hydraulic embossing module is integrated in the rewinding station, and the end surface texture is customized by replacing the embossing roller;
Anti-sticking layer treatment: Add a coating unit at the unwinding station, and realize online spraying of the anti-sticking layer through a modular coating head.

The industry value of modular design: from cost reduction and efficiency improvement to industrial upgrading
Due to the long changeover time of traditional rewinding equipment, enterprises need to reserve a large number of paper cores and coils of different specifications, resulting in high inventory costs. The modular design of the three-station rewinding machine shortens the changeover time by 80%, and enterprises can reduce inventory by 30%. For example, a sanitary products company introduced this equipment, and its annual inventory turnover rate increased from 4 times to 12 times, and its capital occupation cost was reduced by 2 million yuan.

The modular design decomposes the changeover operation into standardized steps and realizes automatic parameter compensation through the PLC system. For example, when changing the paper core specifications, the system automatically adjusts the torque curve of the brake motor to avoid paper breaks or wrinkles caused by sudden changes in tension. After a tape manufacturer applied it, the defective rate dropped from 1.2% to 0.3%, saving 5 million yuan in waste losses annually.

The modular design makes the three-station rewinding machine the core node of the flexible manufacturing system. By integrating with the MES system, the equipment can receive order information in real time, automatically call the corresponding specifications of the segmented rotating seat and linear copper sleeve, and realize "order-driven production". For example, a packaging company built an "intelligent rewinding workshop" through this equipment, shortening the order delivery cycle from 7 days to 24 hours, and increasing customer satisfaction to 98%.

Technology extension: the future evolution of modular design
In the future, the three-station rewinding machine will integrate the AI ​​vision system, automatically identify the specification parameters by scanning the QR code of the paper core and the coil, and command the robot arm to complete the replacement of the segmented rotating seat and the linear copper sleeve. For example, when a new specification of paper core is scanned, the system can predict the optimal tension curve and adjust the drive motor parameters in advance to achieve "zero downtime changeover".

Based on 5G and industrial Internet technology, modular components will be shared in the cloud. For example, an enterprise can upload an idle segmented rotating seat to an industry platform, and other enterprises can rent it on demand to reduce equipment investment costs. The platform can provide component health monitoring services, early warning of wear risks, and extend service life.

The modular design makes the segmented rotating seat and the linear copper sleeve standardized parts, which are easy to recycle and remanufacture. For example, the copper sleeve with a detachable connection structure can be replaced with a bushing for continued use after wear, and the material utilization rate is increased to 95%. In addition, the equipment can convert the mechanical energy in the process of changing the model into electrical energy through the energy recovery system, saving more than 10% energy per year.