Modular Strap Dispenser with Single Feed Motor
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Solution Overview
Problem
Strapping machines require a strap storage box to manage strap feeding efficiently, which increases complexity and cost, and introduces potential misfeed issues due to multiple motorized mechanisms.
Innovation Solution
A modular strap dispenser with a single feed motor and controller that draws strap directly from a spool, feeds it to the strapping machine, tensions, and stores take-up strap in an accumulator box, eliminating the need for a storage box and simplifying the design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a strap storage box with multiple motorized feeding mechanisms is used, then strap supply consistency is improved, but device complexity and cost increase
Solution Approach 1:
The patent combines multiple feeding mechanisms into a single integrated feed system. The single feed motor draws strap directly from the spool and feeds it through the strap chute to the strapping head, eliminating the need for separate input and output feeding mechanisms that would normally require a storage box. This merging of functions reduces complexity while maintaining reliable strap supply.
Solution Approach 2:
The patent extracts and eliminates the strap storage box from the system by designing a direct feed path from the spool to the strapping head. The accumulator box is removed entirely, and the single feed motor directly draws strap from the spool, removing the need for intermediate storage and multiple feeding mechanisms.
2Ease of operation
If multiple motorized feeding mechanisms are used in the storage box system, then strap feeding control is improved, but the risk of misfeeds increases
Solution Approach 1:
By merging multiple feeding control functions into a single feed motor, the system reduces the number of potential failure points. The single motor controls the entire strap feeding process from the spool through the chute to the strapping head, eliminating coordination issues between multiple motors and reducing misfeed risks.
3Productivity
If a storage box is used to maintain unspooled strap, then strap retrieval efficiency is improved, but device complexity increases
Solution Approach 1:
The patent removes the storage box from the system entirely. Instead of storing unspooled strap in a box and retrieving it as needed, the single feed motor directly draws strap from the spool and feeds it through the strap chute to the strapping head, eliminating the complexity of storage and retrieval operations.
Solution Approach 2:
The system performs preliminary action by having the single feed motor continuously draw strap from the spool and feed it through the chute before the strapping head needs it. This eliminates the need for a storage box to hold unspooled strap, as the strap is fed directly from the spool in advance.
Data Source
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AI summary
A modular strap dispenser (1) for a strapping machine (2) comprises includes a mount for rotatably mounting a coiled spool (7) of strap and a feeding mechanism (10) for drawing strap directly from the spool (7), feeding the strap directly to the strapping machine (2) and retracting and tensioning the strap. The feeding mechanism (10) is driven by a variable speed feed motor (11) controlled by a feed motor controller (15). The feed motor controller is operatively connected to a strapper control system that controls both the feed motor controller and the strapping head of the strapping machine. The dispenser may include a braking system (18) to control the rotation of the spool (7). The dispenser also may include an accumulator box(125) configured to accept and store take-up strap generated during strap tensioning. The dispenser may further include a strap guide (120) for guiding the strap from the spool to the feeding mechanism.