Automated Roll Handling Device for Packaging Machines
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Solution Overview
Problem
Existing packaging machines face interruptions and errors during roll changes due to the need for precise positioning of new rolls, which is difficult to achieve, especially with imprecise roll feeds, leading to potential disruptions in the packaging process.
Innovation Solution
A method and device for handling rolls with flat or film material that uses optical sensors and gripping devices, such as multi-axis robots or AGVs, to ensure accurate positioning and exchange of rolls without interruption, even with imprecise feeds, by recording spatial and movement data to control the handling device's movements and using cameras for orientation and damage detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual positioning and remounting of rolls is used to ensure correct rotation direction, then the reliability of material unwinding is improved, but the productivity is worsened due to process interruptions
Solution Approach 1:
The patent applies preliminary action by automatically determining the correct rotation direction of rolls before mounting them to the unwinding mechanism. The control unit pre-processes roll orientation data from sensors and prepares mounting instructions, eliminating the need for manual intervention and ensuring reliable unwinding without interrupting packaging throughput.
Solution Approach 2:
The system implements self-service through automated roll handling where the control unit independently manages roll mounting, rotation direction verification, and position adjustment without human intervention. The sensors and control algorithms enable the system to self-correct roll orientation issues, maintaining both reliability and productivity.
2Manufacturing precision
If precise positioning of new rolls is required during exchange, then the manufacturing precision of roll installation is improved, but the device complexity increases due to additional sensing and control systems
Solution Approach 1:
The handling device achieves universality by using a multi-axis robot that can perform multiple functions: positioning rolls, verifying rotation direction, adjusting roll orientation, and mounting to different unwinding mechanisms. This single versatile system replaces what would otherwise require multiple specialized devices, maintaining precision while managing complexity.
Solution Approach 2:
The system employs feedback mechanisms where sensors continuously monitor roll position, orientation, and rotation direction. The control unit processes this feedback data and automatically adjusts handling parameters to achieve precise roll installation, eliminating the need for overly complex mechanical positioning systems.
3Productivity
If automated handling devices are used for roll exchange, then the productivity is improved by eliminating interruptions, but the ease of operation worsens due to complex control and monitoring requirements
Solution Approach 1:
The automated system performs self-service by independently managing the entire roll replacement process. The control unit automatically determines rotation directions, positions rolls, and coordinates with the unwinding mechanism without requiring operator expertise or intervention, maintaining high productivity while simplifying operation to basic monitoring.
Solution Approach 2:
The patent replaces complex mechanical positioning and alignment systems with sensor-based detection and software-controlled manipulation. Optical sensors and control algorithms substitute for manual measurement and adjustment, making the system easier to operate while maintaining precision and productivity.
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
Enables continuous operation of packaging machines with high automation and error tolerance, ensuring smooth roll replacement and handling of flat or film material without interruptions, even with imprecise roll feeds, by accurately positioning new rolls and detecting potential damage.
Implementation Method 1
at least one optical detection device, in particular a camera (44), which at least detects the movement area (46) of the gripping and/or handling device (16) and provides output signals (40) depicting this movement area (46) and the movements of the gripping and/or handling device (16) taking place within it
Data Source
Figure 1
Figure 2
Figure 3A~3C
AI summary
The invention relates to a method and a device for feeding, providing, handling and/or exchanging rolls (12, 20) having flat and/or film material which is wound onto said rolls and serves as packaging material (22) for the packaging of piece goods, multipacks or similar assemblies of articles. In the device and method, at least approximately completely unwound and/or used up rolls (20) are removed from at least one installation position (EB1, EB2) of a packaging machine (14), whereupon in each case a new roll (12) having flat and/or film material is installed in the installation position (EB1, EB2) in question, wherein new rolls (12) of the packaging machine (14) are provided in a defined feeding and are installed there by means of at least one gripping and/or handling device (16) in the installation position (EB1, EB2) in question, after a used up roll (20) has previously been removed therefrom. At least the positions of the rolls (12) in the region of the defined feeding and/or provision and/or the gripping and/or handling device (16) and/or the movement space (46) thereof are detected by means of space surveillance devices (42) and at least the the movements of the gripping and/or handling device (16) are controlled in the region of the defined feeding and/or provision for the rolls (12) as a function of the acquired spatial, movement and/or sensor data (40).