Packaging Machine Motor-Driven Unwinding for Dancer-Free Web Tension
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Solution Overview
Problem
Existing packaging machines require a dancer individually designed for each machine, leading to complexity and inherent fluctuations in web tension, causing material web damage and compromised sealed connections.
Innovation Solution
A packaging machine that unwinds and transports a material web intermittently using motor-driven supply rolls, synchronizing the speed of the transport means and material web without a dancer, and adjusting motor parameters based on roll parameters to maintain consistent tension.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a dancer is provided downstream of the supply roll to generate web tension, then the material web can be transported along the packaging machine, but the material web becomes significantly stretched, damaged and/or warped
Solution Approach 1:
The patent removes the dancer component from the system entirely. Instead of using a dancer to generate web tension, the supply roll itself is motor-driven, allowing the material web to be unwound without excessive stretching or tension that would cause damage or warping.
Solution Approach 2:
The mechanical dancer system is replaced with a motor-driven supply roll system. The motor provides controlled unwinding of the material web, eliminating the need for mechanical tension generation through a dancer, thereby preventing material web damage while maintaining transport capability.
2Force
If a dancer is provided downstream of the supply roll to generate web tension, then the material web can be transported along the packaging machine, but the sealed connections between the upper material web and the lower material web are damaged during further transport
Solution Approach 1:
The dancer component is removed from the system, eliminating the source of excessive web tension that damages sealed connections. The motor-driven supply roll provides gentle, controlled unwinding that preserves seal integrity during transport.
3Force
If a dancer is provided downstream of the supply roll, then web tension can be generated, but the device complexity increases due to individual design requirements for each packaging machine
Solution Approach 1:
The complex dancer system is completely removed and replaced with a motor-driven supply roll. This eliminates the need for individual dancer design and customization for each packaging machine, significantly reducing device complexity while maintaining web tension control.
Solution Approach 2:
The motor-driven supply roll system is self-regulating, automatically providing the necessary web unwinding without requiring external tension-generating components like dancers. The motor control system adapts to different packaging machines without requiring custom dancer designs.
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
Reduces material web tension, minimizes damage and warping, and ensures precise sealing by eliminating the need for dancers and film brakes, allowing for the processing of thin films and improved seam integrity.
Implementation Method 1
at least one supply roll is driven by a motor
Implementation Method 2
adjusting motor parameters based on roll parameters to maintain consistent tension
Data Source
Figure 1~2
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Figure 5~6
AI summary
The present invention relates to a packaging machine that unwinds a bottom material web from a supply roll and transports it intermittently along the packaging machine. In a forming station, the bottom material web is optionally formed into packaging cavities, which are then covered/filled with a packaged product. Subsequently, a top material web is sealed to the bottom material web in a sealing station. The bottom and top material webs are each unwound from a supply roll, and at least one supply roll is motor-driven. Furthermore, the present invention relates to a method for producing packaging.