Post-Crumpler Jam Detection for Dunnage Flow Continuity
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Solution Overview
Problem
Jamming and interruptions in the flow of paper stock supplied to dunnage machines prevent efficient production of dunnage, leading to delays and potential machine damage, increasing maintenance costs.
Innovation Solution
A device with upstream and downstream jam detectors that stop the drive assembly upon detecting a jam, and a controller that prohibits operation until the jam is cleared, along with a separator to cut the dunnage and prevent further jamming.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If jam detectors are added to detect dunnage jams, then machine reliability is improved, but device complexity increases
Solution Approach 1:
The patent replaces complex mechanical jam detection mechanisms with a vision system using cameras and image processing algorithms. The system captures images of the dunnage material and uses computer vision to detect jams, replacing what would traditionally require mechanical sensors and switches throughout the feed path.
Solution Approach 2:
The patent introduces an image processing algorithm as an intermediary between the camera and the control system. The algorithm analyzes captured images to identify jam conditions, serving as a mediator that translates visual data into actionable detection signals without requiring direct mechanical contact with the dunnage.
2Object-affected harmful factors
If the drive assembly stops upon jam detection, then machine damage is reduced, but productivity decreases
Solution Approach 1:
The patent implements preliminary action by detecting jams before they cause significant damage. The vision system identifies potential jam conditions early in the process, allowing the system to take preventive measures such as adjusting feed rates or alerting operators before actual damage occurs to the drive assembly or separator.
Solution Approach 2:
The patent establishes a feedback loop where the vision system continuously monitors dunnage flow and provides real-time information to the control system. This feedback enables dynamic adjustment of operating parameters to prevent jams while maintaining optimal productivity, rather than simply stopping the entire system.
Data Source
AI summary
A device for producing dunnage includes a jam detector located downstream of a crumpler and upstream of an outlet chute of the device and configured to detect a jam of the dunnage between the crumpler and the outlet chute.