Rear Discharge Mat Rolling Machine with Wrapper Cartridge
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Solution Overview
Problem
Existing mat rolling machines are limited in efficiently rolling large commercial rugs and mats into a cylindrical form with a hollow interior of 3 to 5 inches in diameter, and there is a need for an improved machine that can handle larger rolls and provide better control over the rolling process.
Innovation Solution
A mat rolling machine with a frame and drive belts configured to convey mats in a spiral configuration, using a wrapper cartridge to apply stretch wrap, and sensors to control the rolling process, allowing for adjustable height and precise formation of rolls.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If traditional mat rolling machines are used to roll large commercial rugs and mats, then the machine can form a cylindrical shape, but the hollow interior diameter is limited to 3 to 5 inches and cannot handle larger rolls
Solution Approach 1:
The patent employs dynamically adjustable components including an adjustable hood that can move to different positions, variable speed belts that can change rotation speed, and adjustable finger mechanisms that can modify curvature. These dynamic adjustments enable the machine to handle varying roll sizes and maintain precise control over the rolling process, resolving the contradiction between handling larger volumes and maintaining manufacturing precision.
Solution Approach 2:
The patent changes critical parameters during operation including belt speed, hood position, finger angle, and belt tension. By varying these parameters, the machine can adapt to different mat sizes and desired roll diameters while maintaining consistent rolling quality, allowing transition from 3-5 inch hollow interiors to larger roll configurations.
2Ease of operation
If the machine structure is simplified, then ease of operation improves, but the ability to control the rolling process precisely deteriorates
Solution Approach 1:
The patent incorporates self-regulating mechanisms where the belt system automatically adjusts tension and speed based on the mat being processed, and the hood and finger mechanisms self-position based on programmed parameters. This reduces manual intervention requirements while maintaining precise rolling control through automated parameter adjustments.
Solution Approach 2:
The patent includes control systems that monitor rolling progress and adjust belt speed, hood position, and finger alignment in real-time based on feedback from the rolling process. This feedback mechanism enables precise control without requiring complex manual operations, as the system automatically corrects deviations from desired rolling parameters.
3Productivity
If the rolling speed is increased, then productivity improves, but the stability of the rolled mat deteriorates
Solution Approach 1:
The patent uses dynamically adjustable belt speeds that can be optimized for each stage of the rolling process. The system can maintain higher speeds during straight conveyance phases while reducing speed during critical forming phases where the mat is being shaped, thereby maintaining stability throughout the process while preserving overall productivity.
Solution Approach 2:
The patent employs periodic acceleration and deceleration cycles during the rolling process. The belts and rollers alternate between high-speed conveyance and controlled-speed forming phases, allowing the mat to be efficiently moved during high-speed periods while being carefully formed during controlled periods, thus maintaining both productivity and roll stability.
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
The machine effectively rolls mats into a spiral configuration with adjustable diameter, ensuring efficient handling and storage, and the use of stretch wrap enhances stability and ease of handling.
Implementation Method 1
a wrapper cartridge coupled to the frame, the wrapper cartridge configured to dispense a stretch wrap about the mat in the generally spiral configuration
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. 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. The mat rolling machine may include a wrapper cartridge. The mat rolling machine may include a cutter mechanism.