Bag-Making Machine Film Alignment Automation
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Solution Overview
Problem
The existing bag-making and packaging machines face challenges in efficiently aligning the leading end of a new film roll with the trailing end of a used roll, leading to increased operator workload and complexity in ensuring precise positioning for seamless splicing.
Innovation Solution
The machine incorporates a film supply unit with a rotating mechanism, detection sensor, and control unit that automatically positions the leading end of the new film roll along a predetermined path, utilizing a temporary placement member and restraining mechanism to ensure precise alignment and reduce operator effort.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual alignment of the leading end portion of the first film is performed by an operator, then positioning can be achieved, but the workload of the operator increases and the process becomes complicated
Solution Approach 1:
The patent applies preliminary action by providing a temporary placement member where the leading end portion of the film is temporarily placed before final positioning. This preliminary placement simplifies the subsequent automated alignment process, as the film is already in a known position and orientation, reducing the operator's workload while maintaining operational simplicity.
Solution Approach 2:
The system achieves self-service through the rotating mechanism that automatically rotates the first film roll to convey the leading end portion to the prescribed position. The control unit autonomously controls this rotation based on detection from the leading end portion detection sensor, eliminating the need for manual intervention and reducing operator workload without adding complex alignment procedures.
2Extent of automation
If automated rotation and conveyance mechanisms are added to position the film, then operator workload is reduced, but the device complexity increases
Solution Approach 1:
The rotating mechanism serves multiple functions: it rotates the first film roll to convey the leading end portion to the prescribed position, and can also rotate the entire film roll for splicing operations. This multi-functionality reduces the need for separate mechanisms, thereby limiting the increase in device complexity while achieving high automation of film positioning.
Solution Approach 2:
The temporary placement member acts as an intermediary between the film roll and the bag-making unit. It provides a stable reference point for the leading end portion of the film, enabling the detection sensor and control unit to accurately control the rotating mechanism without requiring complex direct measurement and adjustment systems.
3Manufacturing precision
If the leading end portion is manually positioned while referring to printing, then alignment can be achieved, but the process becomes time-consuming and complex
Solution Approach 1:
The patent replaces the manual visual alignment method with an automated detection system. The leading end portion detection sensor automatically detects when the leading end portion reaches the prescribed position, eliminating the need for operators to visually reference printing and manually adjust positioning. This substitution maintains high alignment precision while dramatically reducing the time required for positioning.
Solution Approach 2:
The control unit receives feedback from the leading end portion detection sensor that continuously monitors the position of the film during rotation. This real-time feedback enables the control unit to automatically stop the rotating mechanism at the precise moment the leading end portion reaches the prescribed position, ensuring high manufacturing precision without time-consuming manual adjustments.
4Ease of operation
If a temporary placement member is introduced for manual positioning, then the positioning process is simplified, but additional components are added to the system
Solution Approach 1:
The film supply process is segmented into distinct functional zones: the temporary placement member for initial positioning, the detection sensor for monitoring, and the rotating mechanism for conveyance. This segmentation allows each component to perform its specific function simply and effectively, making the overall system easier to operate despite the addition of components, as each part has a clear and limited role.
Data Source
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AI summary
A bag-making and packaging machine (1000) includes a film supply unit (100) that supplies film (F) to a bag-making and packaging unit (200). The film supply unit (100) has a film roll holding unit (110a, 110b) that rotatably holds a first film roll (FR), a film temporary placement member (143) on which a vicinity of a leading end portion (F1L) of a first film wound into the first film roll (FR) is manually temporarily placed when attaching the first film roll to the film roll holding unit (110a, 110b), a leading end portion detection sensor (142) configured to detect that the leading end portion (F1L) of the first film is positioned in a prescribed position, and a controller (300) configured to control a rotating mechanism to convey the first film along a predetermined conveyance path until the leading end portion detection sensor (142) detects that the leading end portion of the first film is positioned in the prescribed position.