Dynamic Wrap Force Control for Irregular Load Stability
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Solution Overview
Problem
Conventional stretch wrapping machines face challenges in maintaining consistent containment force due to irregular load geometries and varying demand rates for packaging material, leading to issues like packaging material breaks and inadequate load protection, especially at high speeds and with less experienced operators.
Innovation Solution
A method and apparatus that determine the required wrap force and number of layers of packaging material based on load containment force requirements and material attributes, using a central processing unit to control the wrapping process and ensure consistent application of packaging material throughout the load.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional stretch wrapping machines operate at high speeds with irregular load geometries, then productivity increases, but packaging material breaks and containment force consistency deteriorate
Solution Approach 1:
The system dynamically adjusts the dispensing rate of packaging material based on real-time detection of load geometry and position. The dispensing mechanism transitions from static fixed-rate operation to dynamic variable-rate operation, matching the instantaneous demand caused by irregular load shapes and high-speed rotation, thereby preventing material breakage while maintaining high productivity
Solution Approach 2:
The system incorporates sensors to detect load geometry, position, and wrapping tension in real-time. This feedback information is fed back to the control system, which adjusts the dispensing rate accordingly. The closed-loop feedback mechanism ensures that packaging material is dispensed at the precise rate needed, preventing both breakage and loose wrapping, even at high operating speeds
2Device complexity
If conventional stretch wrapping machines use fixed dispensing rates, then device complexity is reduced, but containment force consistency and wrapping quality deteriorate
Solution Approach 1:
The control system uses feedback from sensors that monitor load geometry, dispenser position, and material tension to automatically adjust dispensing rates. This feedback-driven approach achieves precise containment force consistency without requiring overly complex manual control mechanisms, balancing simplicity with precision
Solution Approach 2:
The system employs microprocessors and embedded controllers that automatically calculate and adjust dispensing parameters based on sensor input. The control system serves itself by making real-time decisions without constant human intervention, achieving precise wrapping quality while keeping the user interface simple and the overall system manageable
3Force
If conventional stretch wrapping machines apply excessive wrap force to compensate for irregular loads, then containment force increases, but packaging material strength requirements and device complexity increase
Solution Approach 1:
Instead of applying excessive force throughout the wrapping cycle, the system dynamically adjusts wrap force based on real-time detection of load geometry and position. The force application transitions from static uniform force to dynamic variable force, matching the instantaneous containment needs of irregular loads without requiring overly complex force control mechanisms
Solution Approach 2:
The system applies different wrap forces to different portions of the load based on local geometry characteristics. Irregular portions requiring higher containment receive increased force, while regular portions receive standard force. This localized force application achieves overall containment force consistency without requiring the entire system to operate at high force levels, simplifying the control system
Data Source
AI summary
Control of a wrapping apparatus is facilitated by enabling an operator to input a load containment force requirement and/or a minimum number of layers of packaging material to be applied to a load, with a wrap control system automatically determining wrap force and other parameters required to meet user input requirements and/or parameters to minimize the expertise required of an operator and to provide more consistent and reliable wrapping of loads. In addition, a wrapping apparatus may be controlled to apply at least a minimum number of layers of packaging material to a load throughout a contiguous region thereof.