Pivoting Roller Wrap Delivery System for Module Builders
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing wrap delivery systems for round module builders often result in uneven distribution of wrap material due to deflection of rollers under stretch force, leading to poorly formed and potentially saturated modules.
Innovation Solution
A pivoting roller system where a second roller is offset and pivotable between two positions, with a biasing member to maintain the wrap material pinched between rollers, ensuring consistent material distribution and tension.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a fixed roller system is used to deliver wrap material, then the structure is simple, but the wrap material distribution becomes uneven due to roller deflection under stretch force
Solution Approach 1:
The roller system transitions from a fixed structure to a dynamic pivoting structure. The second roller is mounted on a bracket that can pivot about a bracket axis, allowing the roller to automatically adjust its position in response to stretch forces applied to the wrap material. This dynamic adjustment prevents roller deflection and maintains even wrap material distribution throughout the wrapping process.
Solution Approach 2:
The system changes the positional parameter of the second roller dynamically during operation. By allowing the roller to pivot between different angular positions, the system adapts the roller's location to compensate for variations in wrap material tension, thereby maintaining consistent distribution without requiring a complex active control system.
2Reliability
If rollers are positioned close together to pinch wrap material, then material tension is maintained, but the system lacks adaptability to stretch force variations
Solution Approach 1:
The second roller is mounted on a pivotable bracket that enables dynamic adjustment of the roller's position. When stretch force is applied to the wrap material, the bracket pivots to reposition the second roller, maintaining the pinching action and consistent tension on the wrap material throughout the wrapping process, regardless of variations in material properties or module size.
3Adaptability or versatility
If a pivoting roller system with offset axis is used, then adaptability to stretch force is improved, but the device complexity increases
Solution Approach 1:
The system employs a simple pivot mechanism rather than a complex active control system. The second roller is mounted on a bracket that rotates about a fixed bracket axis, creating a passive dynamic system that automatically adapts to stretch forces through mechanical motion, minimizing the need for additional actuators, sensors, or control electronics.
Solution Approach 2:
The offset between the bracket axis and the second roller axis creates a mechanical leverage system. When the bracket pivots in response to stretch force, the offset distance translates rotational motion into positional adjustment of the roller, providing adaptability through a simple geometric relationship rather than complex control mechanisms.
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 configuration ensures even wrapping of the module, maintaining its form and preventing moisture ingress by maintaining consistent tension and distribution of the wrap material, resulting in a tightly packed and durable module.
Implementation Method 1
a biasing member coupled to the bracket to bias the second roller in the first position
Data Source
AI summary
A module wrapping assembly for a module builder having a first roller rotationally coupled to the module builder about a first axis, a bracket pivotally coupled to the module builder about a bracket axis, and a second roller rotationally coupled to the bracket about a second axis. Wherein, the second axis is offset from the bracket axis. Further wherein, the bracket is pivotable about the bracket axis to reposition the second axis relative to the first axis.