Dunnage Supply Stabilizer for Roll Collapse Prevention
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Solution Overview
Problem
Existing dunnage conversion systems face challenges in stabilizing rolled sheet material supply units, leading to collapse and jamming issues when the remainder of the roll is extracted, disrupting the continuous feed into the converting station.
Innovation Solution
A stabilizer system that includes a support surface with a tubular roll-receiving space and a resiliently biased support wall to prevent the outer layer of the roll from collapsing, allowing for daisy chaining of rolls and maintaining a stable feed into the converting station.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the remainder of the roll is extracted from the axial opening during dunnage conversion, then the sheet material can be continuously fed into the converting station, but the outer layer of the roll collapses causing jamming and disrupting the continuous feed
Solution Approach 1:
A stabilizer acts as an intermediary component between the roll and the extracting force. The stabilizer includes a support surface with a tubular roll-receiving space that maintains the roll's outer layer in a stable, non-collapsed state during sheet material extraction, preventing jamming while allowing continuous feed into the converting station
Solution Approach 2:
The stabilizer is positioned and configured in advance to receive and stabilize the roll before extraction begins. The support surface is pre-configured with a tubular roll-receiving space that maintains the roll's structural integrity throughout the extraction process, preventing collapse before it can disrupt the feeding operation
2Reliability
If a stabilizer with a support surface is introduced to prevent roll collapse, then roll stability is improved, but the device complexity increases
Solution Approach 1:
The stabilizer employs a flexible support wall that forms a tubular roll-receiving space. This flexible shell structure can adapt to the roll's dimensions while maintaining stability, providing an elegant and relatively simple solution compared to rigid, complex mechanical support structures. The flexible nature allows the stabilizer to conform to the roll without requiring multiple rigid components
Solution Approach 2:
The stabilizer is designed as a separate, modular component that can be independently implemented. The support surface with its tubular roll-receiving space is a distinct element that can be added to existing dunnage conversion systems without redesigning the entire system, thereby limiting the increase in overall device complexity
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 stabilizer system ensures a continuous and uninterrupted feed of dunnage material by preventing roll collapse, reducing jamming, and allowing for efficient conversion of high-density rolls into low-density dunnage material.
Implementation Method 1
The support surface can gently compresses against the outer layer of the roll to prevent collapsing of the roll when the remainder of the roll has been extracted from the axial opening
Implementation Method 2
The support surface can be resiliently biased into the roll-receiving space to press on the outer layer of the roll
Data Source
AI summary
A rolled sheet-material supply handling-system that comprises a drawing device that can be configured to draw sheet material from a supply station and a stabilizer at the supply station. The stabilizer can define a generally tubular roll-receiving space in which a roll of the sheet material can be received and can have a support surface that can define an axial opening leading from the roll-receiving space to receive the sheet material drawn therefrom by the drawing device. The support surface can be sufficiently extensive to stabilize the outer layer of a roll against collapsing when the remainder of the roll has been extracted from the axial opening.