Film-Fitting Device Shot Roller Rotation Control
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Solution Overview
Problem
Existing film-fitting devices for thin tubular films often cause damage and inefficiency due to twisting and require high rotational speeds to ensure proper fitting around bottle containers, leading to increased acceleration time and reduced benefits from circumferential rotation.
Innovation Solution
A film-fitting device with a cutting mechanism, film transfer mechanism, and shot rollers with independent servo or stepping motor drive, allowing for sequential delivery of tubular films while rotating them in the circumferential direction, preventing damage and ensuring reliable fitting by maintaining a predetermined distance and rotational speed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the roller rotates the label in the circumferential direction to deliver it downward, then the label unfolds radially outward and prevents deflation of the lower end part, but the label-forming medium becomes twisted and may be damaged during the period until the label is cut apart
Solution Approach 1:
The delivery process is divided into two distinct phases: first, the label is cut from the label-forming medium while held between the roller and mandrel; second, the cut label is then delivered downward by the roller. This segmentation prevents the label-forming medium from being twisted during the cutting phase, while still allowing the cut label to be properly delivered and unfolded in the second phase.
Solution Approach 2:
The label is cut from the label-forming medium before the rotational delivery action begins. This preliminary cutting action prepares the label in advance, allowing it to be delivered without causing twisting to the remaining label-forming medium. The cut label is then ready to be unfolded and delivered downward by the rotating roller.
2Speed
If the rotational speed of the roller is increased to deliver the label at equivalent speed, then the delivery speed is sufficient, but the acceleration time increases considerably, reducing the benefits of circumferential rotation
Solution Approach 1:
The roller's rotational speed is dynamically adjusted based on the operational phase. During the cutting phase, the roller rotates at a lower speed to prevent twisting. After the label is cut and during the delivery phase, the roller increases its rotational speed to ensure rapid delivery. This dynamic speed adjustment optimizes both film integrity and delivery efficiency.
Solution Approach 2:
The roller operates in periodic cycles: a cutting phase at lower rotational speed followed by a delivery phase at higher rotational speed. This periodic action allows the system to alternate between speed regimes, minimizing acceleration time while ensuring proper label delivery. The roller resets to a lower speed after each delivery cycle to prepare for the next cutting phase.
Data Source
AI summary
A film-fitting device includes a cutting mechanism that cuts a label-forming medium into a predetermined length, a film transfer mechanism that transfers downstream a tubular film arranged around a mandrel, and a shot roller that receives the tubular film transferred by the film transfer mechanism and delivers the tubular film downstream while rotating the tubular film in the circumferential direction. The distance from the cutting mechanism to the shot roller and the distance from the film transfer mechanism to the shot roller are both greater than the length of the tubular film formed by the cutting. Further, rotational drive of the shot roller is carried out by an independent servo motor or stepping motor.