Discontinuous Cut Wrapper Unwrapping Prevents Container Damage
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Solution Overview
Problem
Current methods for automatically unwrapping palletised loads are labor-intensive and prone to system breakdowns due to wrinkles in heat-shrink wrappers, which can cause containers to tilt or break, especially glass containers holding carbonated beverages, as cutting tools often come into contact with the containers during unwinding.
Innovation Solution
A method involving discontinuous vertical and horizontal cuts in the plastics material surrounding the palletised load, allowing the wrapper to be torn in one piece without contacting the containers, using a rotating cutting tool with blades and robotic arms to maintain the integrity of the load and prevent damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If a continuous vertical cut is made in the wrapper and the load is rotated to unwind the plastics material, then the unwrapping process can be automated, but the load tilts and the process fails due to wrinkles or folds in the plastics material
Solution Approach 1:
The continuous vertical cut is replaced with multiple discontinuous vertical cuts separated by uncut portions. This segmentation allows the wrapper to be cut into manageable sections that can be removed without causing the load to tilt or the process to fail due to wrinkles and folds.
Solution Approach 2:
The wrapper is pre-cut with discontinuous vertical cuts before the unwrapping process begins. This preliminary action prepares the wrapper for controlled removal, preventing the load from tilting during the unwrapping operation while still enabling automation.
2Ease of manufacture
If cutting tools are used to make vertical cuts in the wrapper, then the wrapper can be removed, but the cutting tools contact the containers causing damage to glass containers
Solution Approach 1:
Instead of making a single continuous cut that would require the tool to pass through the entire height of the load (contacting containers), the system makes multiple partial discontinuous cuts. Each cut stops before reaching the container level, achieving wrapper removal while preventing container damage.
Solution Approach 2:
The discontinuous cut portions act as intermediaries that allow the cutting tool to remove the wrapper without directly contacting the containers. The uncut portions provide spacing that prevents tool-container contact while still enabling effective wrapper removal.
3Object-affected harmful factors
If manual unwrapping is used, then container damage is minimized, but the process is labor-intensive and involves ergonomic risks for workers
Solution Approach 1:
The system uses automated cutting tools that perform the unwrapping operation themselves through discontinuous cuts, eliminating the need for manual labor. This maintains the benefits of gentle wrapper removal while removing ergonomic risks and labor intensity associated with manual unwrapping.
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 method ensures safe and efficient unwrapping of palletised loads by maintaining the wrapper's integrity and preventing contact with containers, reducing the risk of damage and system stoppages, while allowing for continuous production line operation without rotation of the load.
Implementation Method 1
making vertical and horizontal cuts in a plastics material which surrounds the palletised load
Implementation Method 2
a subsequent step of tearing said discontinuous cut portion
Data Source
AI summary
Method of unwrapping a generally parallelepiped palletised load, which comprises making vertical and/or horizontal linear cuts in a plastics material which surrounds the palletised load, wherein at least one of the linear cuts has a discontinuous cut portion which comprises a plurality of cuts of determined length and constant pitch, the method comprising a subsequent step of tearing said discontinuous cut portion.