Adaptive Stretch Film Wrapping Controller for Load Stability
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Solution Overview
Problem
Existing film wrapping technologies fail to account for the specific characteristics of loads, film properties, and transportation conditions, often resulting in inadequate wrapping that leads to load damage during transportation due to improper containment force and wrapping patterns.
Innovation Solution
A system and method that utilize a film wrapping apparatus with a controller and sensors to determine the discrete stiffness of the film and load characteristics, calculating a recommended containment force and wrapping pattern to ensure proper film application, including variable tension levels across different layers and areas of the load.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If automatic mechanical wrapping equipment is used, then wrapping speed and consistency are improved, but the equipment fails to account for load-specific characteristics, film properties, and transportation conditions, resulting in improper wrapping
Solution Approach 1:
The system dynamically adjusts wrapping parameters including containment force, wrapping pattern, and film tension based on real-time input of load characteristics (weight, size, shape) and film properties (stiffness, elasticity). The controller modifies these parameters during the wrapping process to adapt to specific load requirements and transportation conditions, transforming the static automatic wrapping process into a dynamic, adaptive system.
Solution Approach 2:
The system changes multiple wrapping parameters simultaneously based on input data: containment force is adjusted according to load weight and film stiffness; wrapping pattern (number of layers, coverage area, tension distribution) is modified based on load dimensions and transportation mode; film tension is varied to account for film elasticity and load-specific requirements. This comprehensive parameter adjustment enables the system to adapt automatic wrapping to diverse load characteristics.
2Adaptability or versatility
If human users manually wrap loads, then adaptability to load characteristics is improved, but wrapping consistency and reliability deteriorate due to human error and variability
Solution Approach 1:
The system incorporates sensors and data input mechanisms that continuously monitor wrapping parameters and load characteristics. The controller processes this feedback information and automatically adjusts wrapping parameters in real-time to maintain optimal containment force and wrapping pattern, ensuring consistent and reliable wrapping results without the variability inherent in manual operation.
3Reliability
If too much film is applied to ensure adequate containment, then load containment is improved, but film waste increases and wrapping efficiency decreases
Solution Approach 1:
The system precisely calculates the optimal amount of film required based on load characteristics (weight, size, shape) and film properties (stiffness, elasticity). By dynamically adjusting containment force and wrapping pattern parameters, the system applies the minimum necessary film to achieve adequate containment, preventing both under-wrapping and over-wrapping, thus reducing film waste while maintaining reliability.
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 minimizes load damage by providing a tailored wrapping pattern based on load and film data, ensuring effective containment and reducing the risk of load failure during transportation.
Implementation Method 1
measuring the film while moving the load support or the film dispenser carriage relative to the other to generate the data representing the discrete stiffness of the film
Data Source
AI summary
A method of wrapping a load with a stretch wrapping system utilizes a system for monitoring film properties, a module in the stretch wrapping systems controller to analyze the data or film properties and further utilize the data to determine, at least in part, appropriate machine settings and or wrapping pattern for the film and execute by providing appropriate machine settings such that effective wrapping of the load and proper use of the film are achieved. The film properties include film stiffness.