Rear Discharge Mat Rolling Machine with Segmented Fingers
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Solution Overview
Problem
Existing mat rolling machines are inefficient in rolling large commercial rugs and mats into a cylindrical form, with limitations in the diameter of the hollow interior of the roll and the complexity of the belt systems, leading to a need for an improved design.
Innovation Solution
A mat rolling machine with a frame and multiple drive belts, including primary and secondary fingers, that initiates a roll into a generally spiral configuration, allowing for a larger diameter roll and improved efficiency by using a combination of drive belts and fingers to guide the mat into a spiral shape, with the secondary fingers rotating up and primary fingers remaining down to maintain the roll.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If traditional mat rolling machines use a single set of fingers with fixed radius, then the machine structure is simple, but the hollow interior diameter of the roll is limited to 3-5 inches and cannot accommodate large commercial rugs
Solution Approach 1:
The finger system is segmented into two distinct sets: primary fingers with larger radius and secondary fingers with smaller radius. This segmentation allows the machine to handle large commercial rugs by using the appropriate finger set, thereby increasing the hollow interior diameter capability while maintaining manageable system complexity through modular design
Solution Approach 2:
The finger system is made dynamic by allowing the secondary fingers to rotate upward and out of the way after initiating the roll. This dynamic adjustment enables the transition from a compact initial roll formation to a larger diameter roll configuration, resolving the contradiction between fixed structure limitations and variable size requirements
2Productivity
If mat rolling machines use complex interleaved belt systems, then the rolling function is achieved, but the machine complexity increases and operational efficiency decreases
Solution Approach 1:
The belt system is segmented into four distinct sets of drive belts (first, second, third, and fourth sets), each performing specific functions in the rolling process. This segmentation allows for optimized control of different stages of mat rolling, improving productivity while keeping each individual belt set relatively simple in design
Solution Approach 2:
The drive belts are designed with multi-functionality, where the same belt system can accommodate different mat sizes and types by adjusting operational parameters. The belts serve multiple purposes including feeding the mat, forming the initial roll, and maintaining the rolled configuration, thereby improving overall rolling efficiency without requiring entirely separate systems for each function
Data Source
AI summary
A mat rolling machine for rolling a mat having a leading edge and a trailing edge may include a frame, at least one first drive belt, a plurality of second drive belts, a plurality of third drive belts, and a plurality of fourth drive belts. At least one of the belts may be coupled together at an oblique angle relative to the direction of travel of the belt. The mat rolling machine may include a plurality of primary fingers and a plurality of secondary fingers having a smaller radius of curvature on a lower face than the plurality of primary fingers. The mat rolling machine may include at least one support member for guiding a mat along a path through the mat rolling machine, and at least one pusher for discharging a rolled mat from the rear of the mat rolling machine.