Edge Protector Applicator with Pivoting Breaker Assembly
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for applying corner protectors during strapping operations often result in improper folding and seating, leading to potential tearing or dislodgment, and require additional manufacturing steps and storage space for preformed protectors.
Innovation Solution
A device that folds flat edge protectors to conform to load corners using a shuttle with a breaker assembly, securing them between the strap and load as the strap is tensioned, allowing for simultaneous application and storage on the strapping machine.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If corner protectors are applied during strapping operations using existing methods, then the protectors can be applied to loads, but they do not properly fold along the edge of the load and may not seat properly, leading to tearing or dislodgment
Solution Approach 1:
The breaker assembly performs the folding action on the corner protector before the strap is applied to the load. The movable portion is positioned to fold the protector along the load edge in advance, ensuring proper seating before the strap tensioning process begins, which prevents tearing and dislodgment during strapping operations
Solution Approach 2:
The movable portion of the breaker assembly is designed to move between a first position (generally planar with the fixed portion) and a second position (generally transverse to the fixed portion). This dynamic movement allows the assembly to adapt to the corner protector material and properly fold it along the load edge during the strapping operation
2Reliability
If preformed edge protectors are used, then proper folding is achieved, but additional manufacturing steps are required and excess storage space is needed
Solution Approach 1:
The corner protectors are supplied in a flat, unformed state and the breaker assembly on the strapping machine performs the folding action during normal strapping operations. This self-service approach eliminates the need for separate preforming manufacturing steps while ensuring proper folding, as the protectors are formed exactly when and where they are needed
3Reliability
If preformed edge protectors are used, then proper folding is achieved, but excess storage space is required both in storage and on the strapping machine
Solution Approach 1:
The corner protectors are supplied in a flat state with minimal volume and are folded in-place during strapping operations. This changes the spatial parameter from requiring pre-formed three-dimensional storage to storing flat, compact materials, significantly reducing the volume needed for both storage areas and machine-mounted holders
4Extent of automation
If automated systems are used to position preformed protectors, then application is automated, but the systems are limited in capability
Solution Approach 1:
The breaker assembly is integrated directly into the strapping machine's applicator mechanism, merging the folding function with the existing automated strapping system. This combination allows the system to automatically fold and apply corner protectors using the same actuators and control systems that drive the strapping operation, enhancing both automation extent and adaptability
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 solution ensures proper folding and secure attachment of edge protectors, reducing misapplication and storage needs, while allowing for efficient simultaneous application with strapping operations.
Implementation Method 1
The movable portion is pivotally mounted to the fixed portion. As the shuttle moves off of the home position, the movable portion pivots from the first position to the second position to fold the edge protector to about a 90 degree angle.
Implementation Method 2
The edge protector is received on the load, between the load and the strap, as the strap is pulled onto the load so that when the strap is tensioned, it secures the folded edge protector on the load.
Data Source
AI summary
A device forms and applies an edge protector to a corner of a load as strap is positioned and tensioned around the load, to position the edge protector between the strap and the load. The device includes a shuttle movable between a home position away from the load and an application position near the load. The shuttle includes a breaker assembly having a fixed portion and a movable portion. The movable portion is movable between a position in which it is generally planar with the fixed portion and another position in which it is transverse to the fixed portion. The breaker assembly includes a shoe that defines a receiving region between the shoe and the fixed and movable portions. The shuttle includes a load contact portion. Movement of the shuttle from the home position moves the movable portion from the first to the second position to fold the edge protector. Further movement of the shuttle and contact of the load contact portion with the load discharges the edge protector for receipt on the load as the strap is positioned and tensioned around the load.