Automated Dunnage Feeding With Upstream Material Bending
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Solution Overview
Problem
Existing paper-based dunnage production systems lack efficiency in converting stock material into low-density dunnage, particularly in automated feeding processes, leading to suboptimal packing operations.
Innovation Solution
A dunnage conversion machine with a projection mechanism that bends stock material over faceted surfaces to increase pliability, combined with rollers to form creases and a cutting mechanism for precise dunnage production, facilitating automated and efficient conversion of stock material into dunnage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If stock material is fed directly into the dunnage conversion machine without bending, then the feeding process is simpler, but the material cannot be properly deformed into dunnage
Solution Approach 1:
The projection is positioned upstream of the inlet chute to bend the stock material before it enters the dunnage conversion machine. This preliminary bending action prepares the material for subsequent deformation into dunnage, ensuring proper feed orientation and improving deformation quality without adding complexity within the conversion machine itself
Solution Approach 2:
The intake structure is segmented into distinct functional zones: the projection for initial bending, the inlet chute for material guidance, and the dunnage conversion machine for deformation. This segmentation allows each component to perform its specific function efficiently, with the projection handling preliminary material preparation separately from the main conversion process
2Ease of operation
If the projection bends the stock material, then the material becomes more pliable for dunnage formation, but the intake structure becomes more complex
Solution Approach 1:
The projection applies localized bending action at a specific point upstream of the inlet chute, creating the necessary pliability in the stock material only where needed. This localized intervention achieves the desired material property change without requiring complex mechanisms throughout the entire intake structure
Solution Approach 2:
The projection utilizes curved surfaces to bend the stock material as it passes over, creating the necessary pliability through geometric curvature rather than complex mechanical mechanisms. The curved profile of the projection naturally guides and deforms the material into the required configuration
3Productivity
If automated feeding is implemented, then packing operations become more efficient, but the system requires more complex control mechanisms
Solution Approach 1:
The projection and inlet chute configuration enables the system to automatically guide and position stock material for dunnage formation without requiring external intervention or complex control mechanisms. The material flow is self-regulating through the geometric design of the intake structure, achieving automated feeding through passive mechanical guidance rather than active control systems
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
Enhances the efficiency and automation of dunnage production, allowing for smoother feeding and precise cutting of dunnage pieces, improving packing operations.
Implementation Method 1
The projection is configured to bend the stock material as the stock material passes over the projection
Implementation Method 2
The rollers grip and pull the stock material from the roll or stack, and deform the stock material as the material passes between the rollers
Implementation Method 3
The resulting dunnage can be cut into desired lengths to effectively fill a void space within a container holding a product
Data Source
AI summary
A dunnage conversion machine includes a drive mechanism configured to deform a stock material into a continuous length of dunnage. The machine also includes a cutting device configured to sever a piece of the dunnage from the continuous length of dunnage. The cutting device includes a grip configured to move to a closed position at which the grip exerts a force on the piece of dunnage to retain the piece on the machine until the piece is pulled away from the machine, at which point the grip moves to an open position and the machine advances the continuous length of dunnage to commence another cutting cycle.