3D Load Profiling for Variable Containment in Stretch Wrapping Machines
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Solution Overview
Problem
Conventional wrapping machines struggle to ensure consistent and adequate containment force for loads with non-standard shapes or uneven topography, leading to potential product damage during transit due to insufficient or excessive packaging material use.
Innovation Solution
Implementing automatic load profiling using sensors to determine density and weight parameters, enabling precise control of wrapping parameters such as wrap force and layer thickness, and activating specialized top layer containment operations for non-standard loads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional wrapping machines use manual control parameters for wrap force and layer distribution, then operator flexibility is maintained, but containment force consistency across loads with varied topography deteriorates
Solution Approach 1:
The system performs preliminary scanning of the load to create a three-dimensional profile before wrapping begins. This advance knowledge of the load's topography, corners, and edges enables the control system to pre-calculate and apply appropriate wrap force variations throughout the wrapping process, ensuring consistent containment force without requiring complex real-time adjustments during wrapping
Solution Approach 2:
The patent replaces manual mechanical control of wrap force with an automated optical sensing and computational control system. Sensors scan the load and a controller automatically adjusts wrap parameters based on the scanned profile, substituting human operator control with an automated system that consistently applies optimal containment force across varied load topographies
2Reliability
If excessive packaging material is applied to ensure adequate containment, then load stability during transit is improved, but material waste and wrapping time increase
Solution Approach 1:
The system applies different wrap forces and layer distributions to different regions of the load based on the scanned profile. Areas requiring enhanced containment receive additional material and force, while stable regions receive minimal necessary coverage. This localized quality approach ensures load stability without uniformly excessive material application, reducing overall waste
Solution Approach 2:
The control system dynamically adjusts wrapping parameters such as wrap force, layer count, and material tension based on the scanned load profile. By changing these parameters locally according to actual load characteristics rather than applying fixed parameters, the system achieves adequate containment with optimized material usage, avoiding both excessive and insufficient application
3Ease of manufacture
If the packaging material width is significantly less than the load height with standard spiral wrapping, then the wrapping process is simple, but uneven distribution of packaging material results in weak portions that compromise overall load integrity
Solution Approach 1:
The system transitions from static, uniform wrap parameters to dynamic, variable wrap parameters that adapt to the load's three-dimensional profile. The wrap force, layer distribution, and material tension are continuously adjusted during the wrapping process based on real-time positional data from the scanned profile, ensuring even material distribution and consistent containment across the entire load surface
Solution Approach 2:
The system uses feedback from the scanned load profile to continuously adjust wrapping parameters. The controller compares the actual load topography against the desired wrap pattern and modifies wrap force and layer placement accordingly, ensuring even material distribution and eliminating weak portions that would compromise load integrity
Data Source
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AI summary
The invention relates to a method of controlling a load wrapping apparatus (110) of the type configured to wrap a load (110) on a load support (118) with packaging material (108) dispensed from a packaging material dispenser (106) through relative rotation between the packaging material dispenser (106) and the load support, the method comprising sensing a plurality of points on a plurality of surfaces (736, 738) of the load (110) using one or more sensors (720) directed at the load (110), wherein the one or more sensors (720) includes a digital camera, a range imaging sensor or a three-dimensional scanning sensor.