Automated Dunnage Coiling with Integrated Taping and Ejection
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Solution Overview
Problem
Manual coiling of dunnage materials into coils is time-consuming and can result in inconsistent properties, and existing automated systems lack efficient automated taping and ejection mechanisms to secure and remove the coils effectively.
Innovation Solution
An automated taping mechanism using a guide surface and tape supply to secure the trailing end of the dunnage strip to the coil, combined with an automated coil-ejection mechanism employing a pivotable lever arm to push the coil off the coiling mechanism, facilitating efficient and consistent coil formation and ejection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual coiling is used, then flexibility and simplicity are maintained, but time consumption increases and consistency deteriorates
Solution Approach 1:
The coiling system is divided into distinct functional modules: a coiling mechanism for forming coils, an automated taping mechanism for securing trailing ends, and an ejection mechanism for removing completed coils. This segmentation allows each component to perform its specific function efficiently while maintaining overall system manageability and productivity.
2Productivity
If automated coiling is implemented, then productivity increases, but device complexity increases
Solution Approach 1:
The taping mechanism and ejection mechanism are integrated with the coiling mechanism to form a unified automated coiling system. The taping mechanism combines tape supply, application, and severing functions in one integrated unit, while the ejection mechanism leverages the existing coiling fork structure, reducing overall system complexity despite increased automation.
Solution Approach 2:
The coiling fork serves multiple functions: it guides the leading end of the dunnage strip during coiling formation and later serves as the ejection surface for removing completed coils. This multi-functionality reduces the need for additional specialized components, thereby controlling device complexity while maintaining high productivity.
3Reliability
If automated taping is added, then coil security improves, but device complexity increases
Solution Approach 1:
The taping mechanism operates autonomously without requiring manual intervention. The tape is automatically supplied from the supply roll, applied to the trailing end of the dunnage strip by the guide surface and application mechanism, and severed by the severing mechanism, all through automated coordination with the coiling process, ensuring consistent coil security while minimizing operational complexity.
4Ease of operation
If automated ejection is implemented, then operator intervention is reduced, but device complexity increases
Solution Approach 1:
Instead of actively grasping or pulling the completed coil for ejection, the system inverts the approach by allowing the coil to be pushed off the coiling fork. The ejection mechanism uses a push plate that applies force to the coil, leveraging the coil's own weight and the fork's geometry to achieve automatic removal, thereby simplifying the ejection mechanism while improving ease of operation.
Data Source
AI summary
A dunnage conversion system includes a machine for converting a stock material into a strip of relatively lower-density dunnage, a coiling mechanism for winding the strip into a coil, a taping mechanism for automatically securing a trailing end of the strip to the coil, and a coil ejecting mechanism for automatically removing the coil from the coiling mechanism. The taping mechanism includes a guide surface between an outlet of the machine and the coiling mechanism to guide the strip to the coiling mechanism and to guide tape for engagement with a trailing end of the strip and to secure the trailing end of the strip to the coil. The coil ejecting mechanism includes a lever arm that pivots to push the completed coil off the coiling mechanism.