Hand Wrapper Braking Assembly for Pallet Wrap Tension Control
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Solution Overview
Problem
Conventional handwrapper assemblies fail to maintain consistent tension around corners of pallets or skids during wrapping, leading to product dislodgment and instability, due to excessive rotation and lack of adjustable tension.
Innovation Solution
A handwrapper assembly with a spool and trigger mechanism, featuring a braking assembly with a stopper and adjustable tension system, which limits rotation and maintains tension through a conically shaped stopper and springs, ensuring uniform material dispensing and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional handwrappers are used without tension control, then the device is simple and easy to operate, but the wrapping material rotates excessively causing dips and faults in the wrap
Solution Approach 1:
The brake assembly provides dynamic tension control by allowing the operator to adjust the braking force during the wrapping process. The conically shaped stopper engages with the spindle at different radial positions, enabling variable tension application that adapts to the wrapping situation, particularly when approaching corners of the pallet.
Solution Approach 2:
The invention changes the physical parameter of tension by introducing a adjustable braking mechanism. The conically shaped stopper varies the radial distance from the spindle axis, thereby changing the lever arm length and the resulting braking force. This parameter adjustment allows maintenance of proper tension without excessive complexity.
2Reliability
If static tension is applied between spindle and roll, then some control is achieved, but tension is insufficient around corners causing product dislodgment
Solution Approach 1:
The brake assembly transitions from static to dynamic tension control, allowing the operator to increase braking force when needed during corner wrapping. The conically shaped stopper enables progressive engagement that provides additional tension precisely when the wrap approaches a corner, ensuring product security without complicating normal operation.
Solution Approach 2:
The conically shaped stopper provides mechanical feedback about the wrap's progress around the pallet. As the wrap approaches a corner, the stopper's conical geometry naturally increases the braking force through its varying radial position, providing automatic feedback control that maintains tension without requiring complex electronic sensors or controls.
3Productivity
If the roll of material is heavy and rotation is high, then wrapping speed is maintained, but control of the roll becomes difficult leading to tension loss
Solution Approach 1:
The brake assembly acts as an intermediary control mechanism between the operator and the heavy rolling material. Instead of directly controlling the heavy roll, the operator controls the lighter brake assembly, which then applies controlled resistance to the roll through the conically shaped stopper and spindle interaction, making the heavy material manageable at high speeds.
Solution Approach 2:
The invention replaces direct mechanical control of the heavy roll with a lever-based braking system. The conically shaped stopper creates a mechanical advantage that amplifies the operator's input force, allowing control of the heavy roll through a lighter, more manageable braking mechanism that can be easily operated at high wrapping speeds.
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
The assembly provides adjustable and dynamic tension, ensuring stable and uniform wrapping, reducing product loss and enhancing operational efficiency and safety by maintaining tension around corners and preventing material jostling.
Implementation Method 1
a braking assembly that has a stopper that is operatively connected to the trigger assembly. The braking assembly adjustably limits the rotation of a roll of material that is received on the spool assembly
Data Source
AI summary
The various aspects disclosed herein relate to a handwrapper assembly that provides a braking assembly to limit or prevent rotation of a roll of material when a pallet or skid is wrapped for shipment. The braking assembly may comprise a slidable stopper that engages one or more arms to force the one or more arms to rotate outwardly to engage the roll of material to stop rotation. The handwrapper assembly may also comprise a trigger mechanism to selectively activate the braking assembly such that the amount of friction between the roll of material and the one or more arms is adjustable.