Laundry Folding Line Speed Control for Variable Item Lengths
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Solution Overview
Problem
Existing laundry folding machines face inefficiencies in folding items of different sizes, leading to extended cycle times and unnecessary energy consumption due to uniform transportation speeds and prolonged air blowing durations, which result in incomplete folding and increased noise.
Innovation Solution
Adapting the transportation speed of laundry through the longitudinal-folding station based on item size, allowing smaller items to pass through quickly and larger items to be folded without interruption, while using sensors to monitor the folding process and adjust air blowing duration accordingly to ensure precise folding completion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If all items of laundry are transported through the longitudinal-folding station at the same speed, then the transportation system is simple to operate, but larger items of laundry cannot be folded during uninterrupted onward transportation, extending the cycle time
Solution Approach 1:
The patent applies dynamics by making the transportation speed variable rather than fixed. The control unit dynamically adjusts the transportation speed of the conveyor belt based on the detected length of each laundry item, allowing the system to adapt its operation to different item sizes while maintaining automated folding efficiency
Solution Approach 2:
The patent changes the parameter of transportation speed from a constant value to a variable value that depends on laundry item length. The control unit modifies the speed parameter in real-time based on sensor feedback, enabling larger items to be transported more slowly for complete folding while smaller items pass through quickly
2Manufacturing precision
If the blowing duration is adapted to items of maximum length to ensure complete folding, then all items are definitively folded, but shorter items have unnecessarily long blowing duration causing compressed air to act on already folded items and potentially undo the folding
Solution Approach 1:
The patent changes the blowing duration parameter from a fixed maximum value to a variable value that corresponds to the actual length of each laundry item. The control unit adjusts the air blowing time based on sensor detection, ensuring each item receives exactly the amount of air pressure needed for its size without over-blowing
Solution Approach 2:
The patent implements feedback by using sensors to detect the length of each laundry item and using this information to control the blowing duration. The control unit receives feedback from the sensor about item dimensions and automatically adjusts the air blowing parameters accordingly, creating a closed-loop control system
3Reliability
If the blowing duration is extended to ensure complete folding of all items, then folding reliability is improved, but compressed air consumption increases and unnecessary noise is generated
Solution Approach 1:
The patent optimizes the blowing duration parameter to match the actual needs of each laundry item based on its length. By reducing the blowing duration for shorter items while maintaining adequate pressure for larger items, the system achieves reliable folding without the energy waste of uniformly extended blowing cycles
Solution Approach 2:
The patent applies partial action by providing air blowing only for the duration and intensity necessary for each specific item size. Rather than applying excessive blowing to all items uniformly, the system provides the minimum necessary action for each item, eliminating wasted compressed air while maintaining folding reliability
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 method reduces cycle time, minimizes energy consumption, and ensures complete folding of items of all sizes without interruptions, improving overall folding performance and reducing noise.
Implementation Method 1
a longitudinal conveyor, in particular a circulating conveying belt, for transporting the item of laundry which is to be folded through the longitudinal-folding station in the transporting direction
Implementation Method 2
blowing tubes, in particular blowing tubes with blowing nozzles, for folding the item of laundry which is to be folded over the folding templates by way of compressed air
Data Source
AI summary
In apparatuses for automatically folding items of laundry, items of laundry of different lengths usually are folded in an irregular sequence, resulting in idling and/or delays in particular in the longitudinal-folding station (13). The invention provides for determining the length of each item of laundry (10) upstream of the longitudinal-folding station (13) and for accelerating short items of laundry as they are transported through the longitudinal-folding station (13), whereas larger items of laundry are slowed down in the longitudinal-folding station (13). Following completion of the longitudinal-folding operation, the respectively folded item of laundry is located at the end of the longitudinal-folding station (13) and, immediately following completion of the longitudinal folding, is transported away out of the longitudinal-folding station (13). This avoids unnecessary idling times, and for relatively long items of laundry to be folded longitudinally during continuous, relatively slow onward transportation through the longitudinal-folding station (13).