Horizontal Stretch Wrapping Apparatus Automation
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Solution Overview
Problem
Current methods for horizontally wrapping skids require manual labor, leading to inefficiencies, discomfort, and safety concerns for workers, as well as increased overhead costs due to potential injuries and insurance claims.
Innovation Solution
A horizontal plastic stretch wrapping apparatus with a main frame, control components, electrical enclosure, wrapping arm, and wrap dispenser, powered by a programmable logic controller and motor system, which automates the wrapping process, reducing manual effort and enhancing safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual labor is used to wrap skids with hand plastic wrap dispenser, then flexibility and simplicity are maintained, but worker safety deteriorates and productivity decreases
Solution Approach 1:
The wrapping apparatus performs the wrapping operation automatically without requiring manual intervention. The machine feeds itself with plastic wrap and executes the wrapping cycle autonomously, eliminating the need for workers to physically handle the dispenser and perform bending/stretching motions, thereby resolving the safety contradiction while maintaining operational simplicity
Solution Approach 2:
The patent replaces the manual mechanical system (worker's hands and body movements) with an automated mechanical system. The apparatus uses a motorized arm and automated feed mechanism to perform the wrapping function that previously required manual labor, thus improving safety while maintaining the core wrapping function
2Device complexity
If manual wrapping is performed, then device complexity is minimized, but productivity and worker comfort deteriorate
Solution Approach 1:
The apparatus is designed to be self-sufficient in performing the wrapping operation. It automatically feeds plastic wrap, positions the dispenser, and executes the wrapping cycle without requiring complex external control systems or multiple operators, thereby achieving improved productivity while limiting the increase in device complexity
Solution Approach 2:
The wrapping apparatus is designed to handle various skid sizes and wrapping configurations through programmable control. A single machine can perform multiple wrapping patterns and accommodate different load types, replacing the need for multiple specialized manual operations and improving overall productivity without proportionally increasing complexity
3Productivity
If automated wrapping apparatus is implemented, then productivity and safety are improved, but device complexity and initial cost increase
Solution Approach 1:
The wrapping apparatus is divided into functional modules: a motorized arm assembly, a plastic wrap feed mechanism, a control system, and a frame structure. This segmentation allows each component to be optimized independently and facilitates easier maintenance and operation, thereby improving productivity while managing the perceived complexity through modular design
Solution Approach 2:
The patent introduces a programmable logic controller as an intermediary between the operator and the mechanical components. This controller simplifies the user interface and automates the coordination of multiple mechanical parts, thereby achieving high productivity while shielding the operator from the underlying system complexity
Data Source
AI summary
A horizontal plastic stretch wrapping apparatus includes a main frame, a plurality of control components, an electrical enclosure, a plurality of control buttons, a slip ring, a wrapping arm, and a wrap dispenser. The electrical enclosure and the plurality of control components are positioned within the main frame, and the plurality of control buttons is positioned on the main frame. The plurality of control buttons controls the plurality of control components and the electrical enclosure. The wrap dispenser is connected to the wrapping arm, and the wrapping arm is connected to the main frame. The slip ring is positioned in between the main frame and the wrapping arm and provides electrical power from the electrical enclosure to the wrap dispenser. Once the horizontal plastic stretch wrapping apparatus is powered, a skid can be horizontally wrapped with a wrapping material by the rotating wrapping arm.