Dunnage Machine Exit Chute and Cutter Mechanism
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Solution Overview
Problem
Existing dunnage machines often experience jamming issues at the exit region due to random movement and accumulation of cushioning material, and manual cutting methods can be physically demanding for operators.
Innovation Solution
The dunnage machine features rotatable forming members with circumferential recesses and an exit chute with protruding tongues to guide material flow, reducing jamming, and a manually operated cutter with a pivotable handle and locking mechanism for safe and efficient cutting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If forming members are used to generate cushioning material, then cushioning material is produced effectively, but the material can jam or be caught near the exit region due to random movement and accumulation
Solution Approach 1:
A guide member is introduced as an intermediary component between the forming members and the exit chute. The guide member has a curved surface that guides the cushioning material from the forming members to the exit chute, preventing random movement and accumulation that causes jamming. This mediator component resolves the contradiction by maintaining reliable material flow while preserving effective cushioning material generation.
2Ease of manufacture
If a fixed-blade cutter is used to cut cushioning material, then cutting can be performed with cost advantages, but physical exertion of the operator contributes to fatigue
Solution Approach 1:
The cutting system transitions from a static fixed-blade cutter to a dynamic lever-operated cutter. The lever mechanism allows the operator to apply force at a distance from the blade, creating mechanical advantage that reduces the physical exertion required to operate the cutter. This dynamic system maintains cost-effectiveness while significantly improving ease of operation and reducing operator fatigue.
Solution Approach 2:
The lever-operated cutter allows the operator to apply partial force over a longer distance rather than requiring excessive force directly at the blade. By using the lever arm, the operator can cut through the cushioning material with reduced effort, as the mechanical advantage amplifies the applied force throughout the cutting stroke.
Data Source
AI summary
A dunnage machine and system, and a method of producing dunnage. The dunnage machine can have rotatable forming members with recesses formed thereon. Stationary protruding members can extend into the recesses. A cutting system is provided for cutting dunnage produced by the dunnage machine or system, and a lock mechanism is also provided for locking the cutting system when a cover is removed from the dunnage machine.