Self-Propelled Wrapping Machine with Non-Contact Load Sensing
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Solution Overview
Problem
Existing self-propelled wrapping machines face issues with wrapping loads having irregular profiles or shapes, fragile products, and those not on pallets, due to the feeler element's limitations in detecting vertical outlines and potential for collisions, and require manual operator intervention for load identification and parameter setting, increasing wrapping time.
Innovation Solution
The self-propelled wrapping machine employs sensors to detect the load's surfaces and edges, calculating a wrapping path to avoid collisions and determine optimal film unwinding, enabling automated wrapping without a feeler element, and using a control unit to manage the machine's movement and film unwinding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If a feeler element is used to follow the load outline, then the machine can automatically track the load profile, but it gets blocked by irregular profiles and cannot detect vertical outlines at different heights
Solution Approach 1:
The patent replaces the mechanical feeler element with an optical sensor system (laser scanner or camera) that detects load contours through light reflection or imaging. This substitution eliminates the physical contact problems that caused blocking on irregular profiles while maintaining automatic tracking capability through digital signal processing.
Solution Approach 2:
The patent transitions from a single-point mechanical feeler to a multi-point optical detection system that captures three-dimensional load contours. The sensor array or scanning system detects vertical outlines at different heights simultaneously, adding vertical dimension detection capability that the original feeler element lacked.
2Measurement precision
If a feeler element exerts elastic thrust force to maintain contact with the load, then the machine can follow the load profile, but it causes displacement or damage to fragile or lightweight products
Solution Approach 1:
The patent replaces the contact-based mechanical feeler element with a non-contact optical sensing system using lasers or cameras. This eliminates the elastic thrust force that caused product displacement and damage, while maintaining precise profile detection through optical reflection patterns or image processing.
3Adaptability or versatility
If manual operator intervention is used for load identification and parameter setting, then the machine can adapt to different loads, but it increases wrapping cycle duration
Solution Approach 1:
The patent implements self-service automation where the optical sensor system automatically detects load contours, calculates wrapping parameters, and adjusts machine operations without operator intervention. The system processes sensor data through control algorithms to determine optimal wrapping paths and film application parameters, enabling seamless adaptation to different load configurations.
Solution Approach 2:
The patent performs preliminary automatic load detection and parameter calculation before the wrapping process begins. The sensor system scans and maps the load profile in advance, allowing the control unit to pre-calculate optimal wrapping parameters and prepare the film dispensing mechanism, eliminating setup time during the wrapping cycle.
4Reliability
If the feeler element follows only the lower base portion of the load, then it avoids collisions with protruding objects, but it cannot detect the full vertical outline of the load
Solution Approach 1:
The patent employs a three-dimensional optical sensing approach using laser scanners or multi-angle cameras that capture vertical load contours at multiple heights simultaneously. This multi-dimensional detection capability allows the system to identify protruding objects and calculate safe wrapping paths that avoid collisions while maintaining complete vertical profile awareness.
Data Source
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AI summary
A self-propelled wrapping machine (1) movable around a load (100), for wrapping the latter with a film (50) made of plastic material, comprises a self-propelled carriage (2) provided with guide means (5), a column (6) that is fixed to the carriage (2) and slidably supports an unwinding unit (10) of the film, sensor means (11, 12, 13, 21) to detect surfaces (SI, S2,... Sn) and/or external edges (El, E2,...En) of the load (100) in their total extension and along a detection direction (Z) and process related signals, a control unit (20) to receive the signals from the sensor means (11, 12, 13, 21), calculate a peripheral outline (150) of plan maximum overall dimension of the load (100) on the basis of the surfaces (S I, S2,... Sn) and/or external edges (El, E2,...En), detected in their total extension by the sensor means (11, 12, 13, 21), and process a wrapping path (P) of the wrapping machine (1) around the load (100) on the basis of the peripheral outline (150) so as to avoid collisions with the load (100); the control unit (20) controls the guide means (5) to guide the wrapping machine (1) along the wrapping path (P).