Packaging Machine Film Roll Change Mechanism
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Solution Overview
Problem
Conventional film packaging machines for mattresses are inefficient due to time-consuming film changes and slow operation, as they require a closed film wall for production to continue and involve laborious movement of the take-up roll.
Innovation Solution
A packaging machine with a conveyor and a roller for unwinding packaging material perpendicularly to the conveying direction, allowing the material to wrap around objects, and a mechanical pulling device for simplifying roll changes by eliminating the need for re-welding and re-clamping, enabling modular design and faster roll changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the packaging material is stretched perpendicularly to the conveying direction and wrapped around objects, then the packaging process becomes more efficient, but the film change process becomes more complex
Solution Approach 1:
The film wall is divided into separate sections that can be independently managed. The packaging material is stretched perpendicularly to create discrete segments that can be packaged individually, allowing the film to be changed without affecting the entire system. This segmentation enables the film change process to be simplified despite the perpendicular stretching configuration.
Solution Approach 2:
The system employs dynamic adjustment capabilities where the packaging material can be stretched and repositioned perpendicular to the conveying direction. This dynamic configuration allows the film to adapt to different packaging needs while maintaining efficiency, and the mechanical pulling device can dynamically adjust during film changes without requiring complex reconfiguration.
2Extent of automation
If the take-up roll is moved up and down for film changes, then automatic film changing is achieved, but the operation speed decreases
Solution Approach 1:
The packaging material is pre-stretched perpendicular to the conveying direction before the film change is needed. This preliminary configuration allows the film to be ready for immediate use, and when film changes are required, the pre-positioned material can be quickly replaced without requiring slow, deliberate movements of the take-up roll, thus maintaining high operation speed while achieving automation.
3Reliability
If a closed film wall is produced before production continues, then proper packaging is ensured, but film changes become time-consuming
Solution Approach 1:
The perpendicular stretching of the packaging material creates a continuous film wall that can maintain packaging quality throughout the process. The mechanical pulling device ensures continuous operation by quickly replacing film sections without interrupting the conveying of objects. This continuity allows the system to maintain reliable packaging while minimizing film change time, as the stretched configuration enables faster replacement compared to traditional methods.
4Reliability
If welding portals are kept at the clamping level, then proper sealing is achieved, but roll changes are complicated and acceleration is prevented
Solution Approach 1:
The packaging material is stretched perpendicular to the conveying direction, creating a three-dimensional configuration that separates the welding function from the film change function. This dimensional change allows welding portals to remain at the clamping level for proper sealing, while the perpendicular stretching enables film sections to be independently accessed and changed from above or below, thus improving roll change speed without compromising sealing quality.
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 solution simplifies and accelerates film roll changes, reduces downtime, and allows continuous operation by eliminating the need for re-welding and re-clamping, enhancing the machine's efficiency and modularity.
Implementation Method 1
The packaging material is stretched from this roll essentially perpendicularly to the conveying direction of the conveying device
Implementation Method 2
the conveying device transporting the objects to be packaged against the stretched-out packaging material, so that the essentially rectangular objects unwind the packaging material by entrainment
Implementation Method 3
welding in at least one welding portal provided behind the stretched packaging material in the conveying direction
Data Source
Figure 1~10
AI summary
The machine has conveyor devices transporting rectangular articles (1) to be packaged against a packaging material (3) such that the rectangular articles wind the packaging material by synchronization. A traction device (7) is arranged opposite to a roller (5), which is arranged above or below the conveyor devices. The traction device is provided with a gripping unit for gripping a cut-away edge of the packaging material after separation of the packaging material covering the rectangular articles. A welding portal welds transverse seams left and right of the articles to be packaged. An independent claim is also included for a method for operating a packaging machine i.e. film packaging machine, for an article i.e. mattress.