Horizontal Axis Wrapping Reel Change Unit
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Solution Overview
Problem
Current wrapping systems with horizontal-axis wrapping require manual intervention for reel replacement, leading to increased operational costs and downtime, especially when dealing with small diameter film reels used for packaging toroidal products.
Innovation Solution
An automatic reel change unit is integrated into the wrapping system, comprising a reel storage and a replacement carriage with linear actuators and expandable shafts, allowing for quick and reliable automatic replacement of film reels without operator intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual reel replacement is used in horizontal-axis wrapping systems, then device complexity is reduced, but productivity decreases due to machine downtime and loss of time
Solution Approach 1:
The reel change unit is divided into independent functional modules: a carriage for holding the reel, actuators for movement control, and sensors for detecting reel status. This segmentation allows each component to perform its specific function efficiently while enabling automated operation without requiring the entire system to be overly complex.
Solution Approach 2:
The system incorporates sensors that automatically detect when a reel is depleted and trigger the replacement process without human intervention. The carriage automatically positions and secures new reels, and the system continuously monitors reel status, enabling self-service operation that maintains high productivity while minimizing the need for complex manual intervention systems.
2Adaptability or versatility
If frequent reel replacement is required for small diameter reels, then adaptability to toroidal products is improved, but loss of time increases due to frequent manual intervention
Solution Approach 1:
The system prepares for reel replacement in advance by continuously monitoring reel depletion status through sensors. When a reel is nearly exhausted, the system automatically initiates the replacement sequence, positioning the carriage and securing the new reel before the machine stops. This preliminary action eliminates idle downtime and ensures continuous operation, particularly benefiting applications with small diameter reels that require frequent changes.
Solution Approach 2:
The patent replaces manual mechanical reel replacement with an automated system using electric actuators and sensors. The carriage is moved and positioned automatically through motorized control rather than manual operation, and reel status is detected through optical or proximity sensors rather than visual inspection. This substitution dramatically reduces replacement time and enables the system to handle frequent reel changes required for toroidal product packaging.
3Productivity
If automatic reel replacement system is implemented, then productivity is improved by eliminating downtime, but device complexity increases due to additional components
Solution Approach 1:
The carriage design incorporates multiple functions: it holds the reel during wrapping operations, automatically positions new reels during replacement, and serves as a mounting platform for sensors and actuators. The same mechanical structure performs both wrapping and reel replacement functions, reducing the need for separate dedicated components and minimizing overall system complexity while maintaining high productivity.
Solution Approach 2:
The patent introduces a control system that acts as an intermediary between the sensors detecting reel status and the actuators performing replacement actions. This centralized controller coordinates the sequence of operations, manages the timing of reel changes, and integrates the various components into a cohesive automated system. By using this intermediary control layer, the system achieves high productivity through automation while keeping individual component complexity manageable.
Data Source
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Figure 3
Figure 4~4A
AI summary
It is disclosed a wrapping system with horizontal-axis wrapping employing a plastic film, comprising a winding machine (A) provided with a reel-carrying unit (P) rotatably mounted on a circular path on a substantially vertical plane, the reel-carrying unit (P) comprising at least a support shaft (4) and a tensioning roller (5) arranged parallel at a distance from one another, wherein said system furthermore comprises a reel storage (M), and a replacement carriage (C), the replacement carriage (C) comprising at least a cradle (22), slidable between said storage (M) and said winding machine (A), whereon there are mounted a first drawing carriage (20) for a reel (B1) and a second drawing carriage (21) for a flap of film (F1) of the reel (B1), said first (20) and second (21) carriage being mounted translatable crosswise to said slidable cradle (22) and said second carriage (21) being equipped with gripping means (27) mounted translatable according to an axis having at least a major component in a vertical direction (Z).