Film Accumulation Device with Pendulum Roller Mechanism
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing devices for feeding and accumulating plastic film struggle with efficient transition from a nearly empty reel to a new one, causing production line stoppages and inefficiencies in bagging machines, particularly in the production of plastic pipes.
Innovation Solution
A device with a frame, roller conveyors, and a pendulum mechanism that adjusts the distance between rollers to manage film tension and length, allowing seamless splicing and feeding of film to the bagging machine without stopping, using sensors and motorized components to control the process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual reel replacement and splicing is performed, then the film feeding process can be completed, but the bagging machine must stop and production efficiency decreases
Solution Approach 1:
The device prepares a new reel in advance and performs splicing operations before the current reel is completely exhausted. The accumulation of film loops creates a buffer that allows the bagging machine to continue operating while the reel transition is prepared and executed in the background.
Solution Approach 2:
The device introduces an intermediate accumulation mechanism with rollers and loops that acts as a buffer between the reel and the bagging machine. This intermediary system decouples the reel replacement operation from the bagging operation, allowing them to occur independently without forcing machine shutdown.
2Ease of operation
If the operator stops the machine to replace reels and splice film, then the reel can be changed, but overall production efficiency is reduced
Solution Approach 1:
The device enables automatic or semi-automatic reel replacement and film splicing operations that do not require the bagging machine to stop. The system performs these maintenance operations independently while continuing to supply film to the running machine, eliminating the need for operator intervention that causes production delays.
3Reliability
If film is accumulated in loops between roller conveyors, then continuous feeding is enabled, but device complexity increases
Solution Approach 1:
The device employs a dynamic pendulum mechanism that automatically adjusts the position of roller conveyors based on film tension and loop accumulation. This dynamic adjustment simplifies control by using mechanical feedback rather than complex electronic sensors and actuators, achieving reliable continuous feeding through passive mechanical responses to film state changes.
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
Enables continuous operation of the bagging machine by managing film length and tension, eliminating the need for manual reel changes and reducing production line stoppages.
Implementation Method 1
a pendulum mechanism that adjusts the distance between rollers to manage film tension and length
Implementation Method 2
a pendulum mechanism that adjusts the distance between rollers to manage film tension and length
Implementation Method 3
two roller conveyors, respectively upper and lower, for redirecting the film made of plastic material
Data Source
Figure 1
Figure 2
Figure 3
AI summary
Described is a device for feeding and accumulating film (2) made of plastic material wound on a reel to a bagging machine (4), comprising a frame (9), means for supporting at least one reel (3) of film (2) made of plastic material supported by the frame (9), a first and a second group (G1, G2) of rollers for redirecting the film (2) made of plastic material, the rollers of the first and second group (G1, G2) being arranged in two respective rows parallel to each other, the film (2) being designed to be wound alternatively on the rollers of the two groups (G1, G2) forming a plurality of loops.