Dunnage Conversion Machine Jam Detection Using Optical Sensors
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Solution Overview
Problem
Dunnage conversion machines often experience jams due to material getting stuck, leading to downtime and damage to both the material and the machine, as existing methods fail to detect jams promptly enough to prevent motor damage and efficiently stop the conversion process.
Innovation Solution
A system that monitors the movement of dunnage material with a varying profile using sensors and a controller to detect lack of movement, generating a control signal to stop the conversion process, thereby preventing jams and minimizing damage by identifying potential jams before they cause significant issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing jam detection methods are used, then the machine can operate continuously, but the motor experiences damaging current spikes before the jam is detected
Solution Approach 1:
The patent applies preliminary action by detecting the jam condition through optical sensors before the motor experiences damaging current spikes. The system monitors material movement continuously and stops the motor proactively when a jam is detected, preventing the harmful current surge from occurring in the first place rather than reacting after damage has begun.
Solution Approach 2:
The patent implements feedback by using optical sensors to continuously monitor material movement and providing real-time feedback to the control system. When the sensor detects that material movement has stopped or slowed abnormally, it immediately signals the controller to stop the motor, creating a closed-loop system that prevents jam-related damage through continuous monitoring and responsive action.
2Productivity
If the machine operates without rapid jam detection, then production continues without interruption, but damaged material accumulates requiring cleanup
Solution Approach 1:
The system applies preliminary action by detecting the jam condition before significant material damage occurs. The optical sensors monitor material movement and trigger a motor stop proactively, preventing the accumulation of heavily damaged material that would require extensive cleanup and reprocessing.
Solution Approach 2:
The patent applies the skipping principle by rapidly detecting and responding to jam conditions, rushing through the critical period before significant damage occurs. The quick detection and immediate motor stop minimize the time window during which material can be damaged, effectively skipping the damage accumulation phase.
3Reliability
If optical sensors monitor material profile continuously, then jams are detected early, but the system complexity increases
Solution Approach 1:
The patent uses an intermediary approach by employing optical sensors that non-contactingly monitor the material profile and movement. These sensors act as intermediaries between the material and the control system, providing accurate jam detection without mechanical contact or complex mechanical detection mechanisms, thus maintaining system simplicity while improving reliability.
Solution Approach 2:
The patent applies mechanics substitution by replacing potential mechanical jam detection mechanisms with optical sensing. Instead of using mechanical switches, pressure sensors, or complex mechanical linkages to detect jams, the system uses optical fields to monitor material profile and movement, simplifying the device while enhancing detection accuracy and reliability.
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 effectively prevents material and machine damage by quickly identifying jams and stopping the conversion process, reducing downtime and maintaining production efficiency.
Implementation Method 1
directing a light source against the surface of the dunnage material and using a sensor to detect light reflected from the surface
Data Source
AI summary
A jam-sensing method for a dunnage conversion machine includes the following steps: (a) converting a stock material into a relatively less dense dunnage material having characteristics that vary along the length of the dunnage material; (b) sensing the characteristics of the dunnage material; (c) generating a signal that varies as a function of the sensed characteristics; (d) monitoring the generated signal over time; and (e) generating a control signal when variation in the generated signal within a predetermined period is less than a predetermined amount, which would indicate a lack of movement of the material. This control signal can used to shut down the conversion process, thereby minimizing the extent of the jam condition.