Multi-lane Ice Cream Wrapping System with De-tensioning
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Solution Overview
Problem
Current multi-lane wrappers for ice cream products face issues with reliability, flexibility, and user-friendliness, leading to increased downtime and operational challenges in ice cream production lines.
Innovation Solution
A multi-lane system with reel holders and a web conveying arrangement that includes de-tensioning devices, sliders, and strategically placed reel holders to manage web tension and redirect webs efficiently, reducing the risk of web rupture and enhancing operator handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If web tension is increased to ensure proper feeding to the wrapping machine, then web feeding reliability is improved, but the risk of web rupture increases
Solution Approach 1:
A de-tensioning device is introduced as an intermediary element between the web reel and the wrapping machine. This device temporarily holds and releases the web in a controlled manner, acting as a buffer that decouples the tension source from the feeding point, thereby reducing web rupture risk while maintaining feeding reliability
Solution Approach 2:
The de-tensioning device dynamically changes the tension parameter of the web by storing it under controlled conditions and releasing it at the appropriate moment. This parameter modification allows the web to be fed reliably without experiencing excessive tension that would cause rupture
2Device complexity
If reel holders are placed close to the wrapping machine to simplify the system, then device complexity is reduced, but operator handling difficulty increases
Solution Approach 1:
The reel holders are positioned in a spatial arrangement that optimizes operator access. By strategically placing multiple reel holders at different locations and orientations, the system provides ergonomic access points for operators to load and change reels without requiring them to reach into confined spaces near the wrapping machine
3Productivity
If multiple reels are fed in parallel to increase capacity, then productivity is improved, but web tension control difficulty increases
Solution Approach 1:
The web feeding system is segmented into independent channels, each with its own de-tensioning device. This segmentation allows each web to be tension-controlled independently, preventing the complexity of coordinating multiple webs while maintaining high productivity through parallel operation of multiple lanes
Data Source
Figure 1a
Figure 1b
Figure 1c~1d
AI summary
A multi-lane system (100) for wrapping ice cream products (202) is presented. The system comprises reel holders (102) for receiving reels (104) holding webs (106) of packaging material, a wrapping machine (110) arranged to receive the ice cream products (202), to receive the webs (106), to enclose the ice cream products (202) in the webs (106) and to seal the webs (106) such that wrapped ice cream products (204) are formed, and a web conveying arrangement (108) arranged to individually feed the webs (106) of packaging material from the reels (102) to the wrapping machine (110). The web conveying arrangement (108) comprises de-tensioning devices (112) arranged to decrease tensions in the webs (106) upstream the wrapping machine (110) .