Dual-Path Bag Winding for Tension and Overlap Control
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Solution Overview
Problem
Existing bag-making machines face inefficiencies in winding and processing webs of material into pouches or bags, particularly in terms of tension control, overlapping, and forming consistent seals, which affect the quality and efficiency of the bag production process.
Innovation Solution
A winder system with a diverter mechanism and air system to control bag winding paths, combined with a sealing section and banding process, ensures precise tension management and consistent bag formation, allowing for efficient conversion of web material into bags.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single winding path is used for bag winding, then the device structure is simple, but the productivity is limited due to single-sided operation
Solution Approach 1:
The winder is divided into two independent winding stations (first and second winding paths), each capable of operating independently to wind bags onto separate rolls. This segmentation allows continuous operation where while one station is winding, the other can be serviced or preparing, thereby doubling productivity without requiring a complete system redesign
Solution Approach 2:
Two winding paths and their associated spindles are merged into a single integrated winder unit sharing common support structures, control systems, and space. This combining approach enables dual-sided operation for improved productivity while avoiding the complexity of completely separate winding machines
2Stability of the object's composition
If bags are wound tightly to improve roll compactness, then the roll stability is improved, but the tension in the web material increases causing deformation
Solution Approach 1:
The winding tension is made dynamic rather than static, with the system automatically adjusting tension levels based on the winding phase and bag characteristics. During initial winding, higher tension ensures compact roll formation, while tension is reduced as the roll builds to prevent material deformation and damage to sealed edges
Solution Approach 2:
The winding parameters including tension force, winding speed, and layer arrangement are changed and optimized throughout the winding process. The system transitions from high-tension initial winding for roll stability to lower-tension subsequent winding to protect material integrity, with parameters adjusted based on real-time monitoring
3Productivity
If the diverter operates at high speed to improve productivity, then the bag processing throughput increases, but the bag positioning precision decreases
Solution Approach 1:
The diverter operates in periodic cycles with distinct phases: high-speed diversion for most of the bag sequence, followed by a brief low-speed positioning phase when a specific bag needs to be diverted to the overlap station. This periodic variation in speed maintains high overall throughput while ensuring precise positioning when required
Solution Approach 2:
The system identifies and prepares for precision positioning in advance by monitoring bag counters and predicting when a bag requires diversion to the overlap station. The diverter begins slowing down before the critical positioning point is reached, allowing smooth deceleration and accurate placement without disrupting the overall high-speed workflow
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 system enhances the quality and efficiency of bag production by ensuring consistent tension, overlapping, and sealing, resulting in improved bag formation and winding processes.
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 may be included. Related methods are further disclosed.