Encoder Mount on Hinged Door for Pallet Wrapping Film Measurement
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Solution Overview
Problem
Existing pallet wrapping systems face inaccuracies in monitoring stretch film usage due to slipping issues and require user intervention for sensor resetting and placement, leading to potential errors and damage.
Innovation Solution
A pallet wrapping system with a pre-stretch carriage featuring two driven stretch rollers and a hinged door with encoders mounted on the door, which automatically measure stretch film length without user intervention, reducing slipping and protecting the sensors from damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a spring-loaded sensor is placed on the outside surface of the stretch film roll to measure film length, then measurement accuracy is improved, but the device complexity and user intervention requirements increase
Solution Approach 1:
The encoder system automatically measures stretch film usage through the pre-stretch carriage rollers without requiring user intervention for sensor placement or resetting. The system self-activates when the carriage operates, eliminating manual setup steps and reducing complexity while maintaining measurement accuracy.
Solution Approach 2:
The patent replaces the spring-loaded contact sensor with an optical encoder that measures film usage non-contactually through the carriage structure. This substitution eliminates the mechanical contact and spring mechanism, reducing device complexity while preserving measurement precision.
2Measurement precision
If a spring-loaded sensor is used to track stretch film length, then measurement accuracy is improved, but the reliability decreases due to potential sensor damage
Solution Approach 1:
The pre-stretch carriage structure serves as an intermediary between the encoder and the stretch film. The encoder mounts to the carriage and measures film passage indirectly through the carriage's interaction with the film, protecting the encoder from direct contact with the film roll and potential damage.
Solution Approach 2:
The patent replaces the fragile spring-loaded contact sensor with a more durable optical encoder system that operates without direct mechanical contact to the film roll, improving reliability while maintaining measurement precision.
3Measurement precision
If the sensor is placed on the roll of stretch film, then measurement accuracy is improved, but ease of operation worsens due to manual resetting requirements
Solution Approach 1:
The encoder system integrated with the pre-stretch carriage automatically activates and begins measuring when the carriage operates. No user intervention for resetting or repositioning is needed, as the system self-activates through the mechanical operation of the carriage, greatly improving ease of operation.
4Measurement precision
If the hinged door entrap the stretch film between rollers and door, then measurement accuracy is improved, but device complexity increases
Solution Approach 1:
The hinged door serves multiple functions: it provides access to the pre-stretch carriage interior, protects internal components, and acts as a measurement surface for the encoder. This multi-functionality reduces overall device complexity by combining several functions into a single component.
Data Source
AI summary
A pallet wrapping system with a pre-stretch carriage and at least two encoders. The pre-stretch carriage is configured to pre-stretch stretch film and has at least two stretch rollers and a hinged door. The at least two stretch rollers includes a first stretch roller with an outer surface that moves at a first speed and a second stretch roller with an outer surface that moves at a second speed higher than the first speed. The door provides access to the stretch rollers when in an open position and entraps the stretch film between the stretch rollers and the door when in a closed position. The encoders are mounted on the door. Each of the encoders is configured to contact the stretch film on the outer surface of one of the stretch rollers and measure a length of stretch film passing over that stretch roller.