Bow Spreader Bar with Remote Actuators for Film Processing
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Solution Overview
Problem
Existing bow spreader bars in plastic film processing are complex, costly, and require frequent maintenance due to their roller-based design, which leads to creases and wrinkles in the film, and they often necessitate manual adjustments in difficult locations.
Innovation Solution
A motorized, non-rotating bow spreader bar with an elongated arcuate member and low-friction surface, featuring remote actuators for adjusting pitch angle and bowing, allowing for adjustments from a safe distance using a wireless remote controller, reducing the need for manual intervention and minimizing maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a roller-based bow spreader design is used, then the film web can be stretched transversely to eliminate creases and wrinkles, but the device becomes complex, costly, and requires frequent maintenance
Solution Approach 1:
The patent removes the rollers from the bow spreader design, extracting the problematic rotating components that caused complexity and maintenance issues. The bow spreader becomes a static arcuate bar that directly contacts the film web through its rounded surface, eliminating the need for roller assemblies, bearings, and drive mechanisms while maintaining the film-stretching function.
Solution Approach 2:
Instead of using rotating rollers to contact the film, the invention inverts the approach by using a static arcuate bar with a rounded surface that the film slides against. This reversal of the contact mechanism eliminates the complexity of rotating parts while achieving the same transverse stretching effect.
2Adaptability or versatility
If manual adjustment of the bow spreader is implemented, then the pitch angle and arc can be adjusted, but workers must access difficult and potentially dangerous locations
Solution Approach 1:
The patent introduces a remote control system with a transmitter and receiver as an intermediary between the operator and the bow spreader adjustment mechanisms. The receiver is mounted on the spreader bar and wirelessly controls the actuators, allowing operators to adjust the pitch angle and arc from safe, accessible locations without needing to physically access elevated or dangerous areas.
Solution Approach 2:
The invention replaces manual mechanical adjustment with an automated actuator system controlled by a remote receiver. Motors or actuators are mounted on the spreader bar to automatically adjust the pitch angle and arc based on wireless signals, eliminating the need for manual intervention in difficult-to-reach locations.
3Speed
If powered rollers are used to match line speed, then the film can be properly stretched, but the device requires speed sensors, feedback circuits, and increased complexity
Solution Approach 1:
The patent removes the powered rollers and their associated speed sensors, feedback circuits, and control systems. The static arcuate bow spreader maintains film contact through its rounded surface without requiring active drive mechanisms, thereby eliminating the complex control infrastructure needed to match line speed while still achieving effective film stretching.
4Reliability
If rollers are used on the bow spreader, then film contact can be maintained, but wear occurs from rollers rubbing against each other and the film
Solution Approach 1:
The patent eliminates the rollers entirely, replacing them with a static arcuate bar featuring a rounded contact surface. This removes the rolling and rubbing motion between rollers that caused wear, extending the service life of the spreader bar while maintaining continuous film contact through the rounded surface geometry.
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 simplifies and streamlines the adjustment process, reducing maintenance needs and eliminating creases and wrinkles in the film, while enabling safe and efficient operation by allowing remote control of the bow spreader bar, thus enhancing film processing efficiency and safety.
Implementation Method 1
The rounded surface has a low-friction treatment applied to it so that the film web slides past
Data Source
AI summary
A bow spreader bar provides lateral stress on a web of plastic film as it travels past. An elongated arcuate bow member is supported on a rotatable support bar that can be rotated by a first actuator to adjust pitch angle of the bow member relative to the plane of the film. A second actuator mounted on a midportion of the rotatable bar has a rod connected to a center part of the arcuate member and adjusts the amount of bow or arc of the arcuate member. A remote control arrangement has a receiver coupled to the first and second actuators and a remote transmitter permitting an operator to control the pitch angle and amount of bow from a location remote from the film processing equipment.