Dunnage Conversion Machine Crumpling Control
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Solution Overview
Problem
The randomness of crumpling in sheet stock material during dunnage conversion leads to loose shards, increasing the likelihood of jamming, waste, and interference with optical sensors, as cutting blades move through planes with crumpled material.
Innovation Solution
A dunnage conversion machine with a conversion assembly that advances sheet stock material, selectively crumples it, and then temporarily reduces crumpling in a portion before cutting, using a controller to manage the feed and connecting assemblies to minimize crumpling and prevent shard generation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the sheet stock material is randomly crumpled during conversion, then the dunnage product achieves desired density and loft, but loose shards are produced during cutting that increase jamming and waste
Solution Approach 1:
The cutting process is segmented into two distinct phases: first cutting the crumpled dunnage product to desired length, then separately removing loose shards. This segmentation allows the cutting blade to work with the crumpled material structure while providing a subsequent cleanup step to remove generated shards, resolving the contradiction between maintaining dunnage density and preventing waste.
Solution Approach 2:
A shedding surface is introduced as an intermediary element between the cutting blade and the collection area. This shedding surface allows loose shards to be deposited and then easily removed, acting as a mediator that separates the cutting operation from the waste accumulation problem, enabling continuous operation without jamming.
2Shape
If the sheet stock material is randomly crumpled during conversion, then the dunnage product achieves desired loft and cushioning properties, but optical sensors are interfered with by loose shards
Solution Approach 1:
The shedding surface serves as an intermediary that intercepts loose shards before they can reach and interfere with optical sensors. By providing a designated shedding area, the system prevents shards from becoming airborne or contacting sensitive components, thus protecting the optical sensing system while maintaining the crumpled dunnage structure.
Solution Approach 2:
Loose shards are extracted from the main dunnage product stream through the shedding mechanism. The shedding surface allows shards to be separated and removed from the crumpled dunnage material, preventing them from interfering with optical sensors while preserving the intact dunnage products for use.
3Productivity
If the cutting blade moves through crumpled material, then discrete dunnage products can be severed, but jamming increases due to loose shard accumulation
Solution Approach 1:
The shedding surface acts as an intermediary collection point that prevents loose shards from accumulating in the cutting path and causing jams. By providing a dedicated shedding zone, the system maintains continuous operation while allowing periodic or continuous removal of shards, thus preserving productivity without sacrificing reliability.
Solution Approach 2:
The system continuously discards loose shards through the shedding mechanism, preventing their accumulation. This ongoing removal process ensures that the cutting operation can proceed without interruption from jams, maintaining both productivity and reliability by constantly clearing potential problem areas.
Data Source
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AI summary
A dunnage conversion machine converts a sheet stock material into a dunnage product that is relatively thicker and less dense than the stock material. The conversion machine includes a conversion assembly that draws the sheet stock material therethrough and randomly crumples at least a portion of the sheet stock material. Before severing a discrete dunnage product of a desired length from the substantially continuous length of sheet stock material, the random crumpling is minimized or eliminated in an area to be cut.