Foil Carriage Pendulum Roller Tension Control
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Solution Overview
Problem
Existing film winding devices face challenges in maintaining even film tension, especially when using bio-based polymers, which tend to slip, and at higher winding speeds, due to varying packaged goods geometries, leading to undesirable tension peaks and limited throughput.
Innovation Solution
The film carriage incorporates a pendulum roller with an adjustable lever arm and separate pressure rollers for the driver and brake rollers, connected to a common control loop, allowing for quick tension adjustments and improved friction, enabling reliable tension control independent of packaged goods geometry.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If sensor-based control systems are used to adjust film tension, then film tension can be adjusted during the winding process, but the control response is too slow at higher winding speeds to effectively compensate for sudden film tension peaks
Solution Approach 1:
The patent replaces sensor-based electronic control systems with a mechanical feedback system using a pendulum roller and lever arm. The pendulum roller's position changes in response to film tension variations, and this mechanical displacement is directly transmitted through the lever arm to actuate the brake roller, eliminating the need for slow electronic sensing and processing at high speeds
Solution Approach 2:
The pendulum roller automatically responds to film tension changes without external sensing or control intervention. The system uses the film tension force itself to actuate the control mechanism, creating a self-regulating system that inherently responds to tension variations regardless of winding speed
2Object-generated harmful factors
If bio-based film material is used, then sustainable packaging is achieved, but film slippage increases which severely limits possible throughput rates
Solution Approach 1:
The pressure roller applies preliminary frictional force to the drive roller before film slippage occurs. This continuous pressure ensures that the film is firmly gripped and prevents slippage from occurring in the first place, allowing bio-based materials to be processed at high speeds without losing traction
Solution Approach 2:
The system changes the friction parameter between the film and drive roller by applying pressure through the pressure roller. This increases the friction coefficient, preventing slippage of bio-based films and enabling higher throughput rates
3Adaptability or versatility
If packaged goods with varying geometries are wrapped, then product versatility is achieved, but undesirable film tension peaks occur due to sharp corners and irregular shapes
Solution Approach 1:
The pendulum roller creates a mechanical feedback loop where film tension variations caused by packaged goods geometry automatically adjust the brake roller position. When tension peaks occur at sharp corners, the pendulum roller displaces, increasing brake pressure to compensate and maintain uniform tension throughout the wrapping process
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
This solution enables rapid and sensitive film tension adjustments, even at higher speeds, reducing tension peaks and allowing the use of bio-based materials without throughput limitations, while maintaining constant clamping forces and accommodating various packaged goods shapes.
Implementation Method 1
The adjustment to both the drive roller and the brake roller, each with the aid of a separate pressure roller, causes the film web to be pressed against the drive and brake rollers to achieve a higher friction coefficient, which improves force transmission.
Implementation Method 2
This allows the position of the pendulum roller to be determined and, subsequently, the position of the pendulum roller to be influenced depending on the rotational speed of the driver roller. The pendulum roller is thus subjected to a corresponding pretensioning force by the actuator, independently of the winding speed specified by the winding device drive.
Data Source
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AI summary
A film carriage (1) for a winding device is described. The film carriage comprises several deflection rollers (2, 3, 4, 5, 6), a driver roller (7) and a brake roller (8) positioned upstream of it in the film take-off direction (F), wherein the driver roller (7) and the brake roller (8) each have a separate drive (9, 10).According to the invention, it is proposed that both the driver roller (7) and the brake roller (8) are each assigned an adjustable pressure roller (11, 12), and that a pendulum roller (15) is provided downstream of the driver roller (7) in the film take-off direction (F), which is arranged at the free end of a lever arm (16) articulated to the film carriage (1) and actuated by means of at least one actuator (18), wherein, for adjusting the film tension, the at least one actuator (18), as well as the respective drives (9, 10) of the driver roller (7) and the brake roller (8) are connected to a control device in a common control loop for position control of the pendulum roller (15).