Dynamic Dispensing Rate Control for Packaging Material Wrapping
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Solution Overview
Problem
Existing packaging systems face challenges in maintaining consistent wrap force and containment force during high-speed wrapping due to irregular load geometries and center offset, leading to packaging material breaks and inefficiencies in material usage.
Innovation Solution
The system controls the dispensing rate of packaging material based on corner rotation angles, using sensors to track corner positions and adjust the dispensing rate to match the effective consumption rate of the load, thereby minimizing force fluctuations and optimizing containment force.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If constant packaging material dispensing rate is used during rotation, then packaging material supply is simplified, but packaging material breaks occur due to mismatch between supply rate and demand rate variations caused by irregular load geometry
Solution Approach 1:
The dispensing rate is dynamically adjusted during the wrapping cycle based on the rotational position of the load. The system transitions from a static constant rate to a dynamic variable rate that responds to changing geometric conditions, specifically modifying the dispensing rate when corners approach the dispenser to prevent material breaks while maintaining reliability.
Solution Approach 2:
The system uses feedback from corner detection sensors to monitor the rotational position of the load and adjusts the dispensing rate accordingly. When a corner is detected approaching the dispenser, the system increases the dispensing rate in advance, creating a closed-loop control system that prevents packaging material breaks by responding to actual load conditions.
2Force
If high wrap force is applied to achieve better containment, then containment force improves, but packaging material breaks increase due to excessive tension on irregular geometries
Solution Approach 1:
The system dynamically changes the dispensing rate parameter during the wrapping cycle based on the rotational position of load corners. By increasing the dispensing rate when corners approach the dispenser, the system reduces instantaneous tension on the packaging material while maintaining overall high wrap force, thereby preventing breaks and improving material integrity without sacrificing containment effectiveness.
3Reliability
If dispensing rate is increased to meet peak demand during corner passages, then packaging material breaks are reduced, but loose wrapping occurs during other portions of the rotation
Solution Approach 1:
The system applies periodic modulation to the dispensing rate that corresponds to the rotational cycle of the load. The dispensing rate is increased periodically when corners approach the dispenser and reduced during side passages, creating a rhythm that matches the load geometry. This periodic adjustment prevents both material breaks and loose wrapping by ensuring tightness consistency throughout the entire wrapping cycle.
Data Source
AI summary
A wrapping apparatus and method utilize a corner rotation angle-based wrap control that controls the rate at which packaging material is dispensed based on the rotational position of one or more corners of the load determined during relative rotation established between the load and a packaging material dispenser.