Bag Winding Path Diverter for High-Throughput Roll Making
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Solution Overview
Problem
Existing bag-making machines face challenges in efficiently converting a web of material into pouches or bags, particularly in the winding and sealing processes, leading to inefficiencies and inconsistencies in the formation and packaging of bags.
Innovation Solution
A machine and method that includes a winder with a diverter and conveyors to selectively direct bags along different winding paths, an air system to assist in winding, and a bander to apply banding material, along with a sealing section to form bags from a web of material, ensuring precise and efficient formation and packaging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single winding path is used in existing bag-making machines, then the device structure is simple, but the productivity is limited due to inability to process multiple bags simultaneously
Solution Approach 1:
The patent divides the single winding path into multiple separate winding paths (first winding path and second winding path), each capable of processing bags independently. This segmentation allows simultaneous processing of multiple bags along different paths, thereby increasing productivity while maintaining manageable device complexity through modular path design
Solution Approach 2:
The patent introduces a diverter mechanism that can redirect bags between different winding paths, adding a dimensional aspect to the bag flow. This allows the system to dynamically allocate bags to different paths based on processing needs, effectively increasing throughput without proportionally increasing overall system complexity
2Manufacturing precision
If conventional sealing methods are used, then the device structure is simple, but the manufacturing precision of bag formation is inconsistent
Solution Approach 1:
The patent replaces conventional mechanical sealing methods with ultrasonic sealing technology. The ultrasonic sealer uses high-frequency vibrations to melt and fuse the web material, creating consistent and reliable seals. This substitution of sealing mechanism significantly improves manufacturing precision and sealing consistency while the modular design keeps device complexity manageable
Solution Approach 2:
The ultrasonic sealing process utilizes controlled changes in vibration frequency, amplitude, and duration to achieve consistent sealing results. By precisely controlling these parameters, the system ensures uniform seal quality across all bags, thereby improving manufacturing precision without requiring overly complex mechanical structures
3Productivity
If manual bag handling is used, then the device complexity is low, but the productivity and manufacturing efficiency are reduced
Solution Approach 1:
The patent implements an automated system where the diverter mechanism self-regulates bag distribution between winding paths based on real-time processing conditions. The air system automatically assists in bag separation and positioning without requiring manual intervention. This automation increases productivity while the self-regulating nature of the system prevents excessive complexity
Solution Approach 2:
The patent employs an air system that uses pneumatic pressure to assist in bag handling, separation, and positioning during the winding process. This pneumatic assistance enables faster and more consistent bag processing compared to manual handling, increasing productivity while maintaining relatively simple system architecture through the use of gas-based actuation
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
The solution enables precise and efficient conversion of a web of material into bags, improving the winding and sealing processes, resulting in consistent and high-quality bag production.
Implementation Method 1
an air system is configured to pull a leading end of a leading bag in the bags conveyed along the first winding path onto the first spindle. Optionally, the first spindle has a plurality of holes such that the air system creates a vacuum that pulls air through the plurality of holes and pulls the leading bag onto the first spindle
Data Source
AI summary
A machine for processing a web of material into bags includes several sections for processing the web of material into bags. An input section is configured to receive a roll of the web of material, a sealing section is configured to form seals in the web of material, and a winder section configured to wind the bags into rolls of bags may be included. A bander section configured to band each roll of bags may be included. A hem forming section configured to form a hem in the web of material may be included. A draw tape unwind station for unwinding draw tape for bags maybe included. Related methods are further disclosed.