Reel Side Pattern for Packaging Machine Position Tracking
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Solution Overview
Problem
Existing roll-fed packaging machines face challenges in providing cost-efficient and reliable continuous information about the operation, particularly in determining the remaining number of packages that can be produced before a reel needs replacement.
Innovation Solution
A packaging material arrangement with a reel-specific two-dimensional printed pattern on its ring-shaped side surface, allowing a sensor to determine the rotational position and identify the reel, coupled with a control device that retrieves data from a database to track the number of sub-portions remaining on the reel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If RFID tags are used on reels to provide information about packaging material, then machine settings can be adjusted automatically, but the RFID tag adds extra cost to both the reel and the packaging machine and may be difficult to read
Solution Approach 1:
The patent uses a printed pattern on the reel as a visual copy or alternative representation of the identification information. Instead of using RFID tags that store data electronically, the invention creates a visual duplicate of the reel identification through patterns that can be read by optical sensors, providing a reliable and cost-effective alternative that eliminates reading reliability issues while maintaining automation capability
Solution Approach 2:
The patent replaces the electromagnetic RFID reading system with an optical sensing system that reads printed patterns. This substitution uses light-based detection instead of electromagnetic field-based detection, eliminating the reliability problems associated with RFID reading while maintaining the ability to automatically identify reels and adjust machine settings
2Loss of information
If codes are provided on each sub-section of the packaging material to enable tracing, then increased information about sub-section positions is provided, but this approach comes with extra cost
Solution Approach 1:
The patent extracts the essential identification function from the complex system of individual sub-section codes and concentrates it in a single printed pattern on the reel. By taking out only the necessary identification information and placing it on the reel itself, the invention provides sufficient tracking capability without the excessive cost of coding every sub-section
Solution Approach 2:
The printed pattern on the reel serves multiple functions: it identifies the specific reel, provides information about the packaging material, and enables tracking of the reel's position and status. This single multi-functional element replaces the need for multiple individual codes on each sub-section, reducing manufacturing cost while maintaining comprehensive information availability
3Measurement precision
If a sensor reads the printed pattern on the reel to determine rotational position, then accurate monitoring of remaining packages is achieved, but the system complexity increases
Solution Approach 1:
The patent uses a simple printed visual pattern on the reel that creates a clear optical signature for position detection. This visual copy provides distinct reference points that are easy for the sensor to detect and interpret, achieving high measurement precision without requiring complex sensor systems or sophisticated signal processing
Solution Approach 2:
The patent changes the physical parameter of the reel by adding a printed pattern that alters its optical properties. This simple parameter change enables the sensor to detect rotational position through light reflection or absorption variations, achieving accurate measurement while keeping the sensor system relatively simple compared to using complex encoders or multiple sensors
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
Enables accurate and cost-effective monitoring of the number of packages left on a reel, facilitating efficient operation and reducing the need for manual intervention by providing real-time status updates.
Implementation Method 1
a sensor arranged to read the printed pattern of the ring-shaped side surface of the reel such that a rotational position of the reel with respect to the reel receiver can be determined
Data Source
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Figure 3
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AI summary
A packaging material arrangement (102) for a roll-fed packaging machine (100) is provided. The arrangement (102) comprises a reel (300) formed as a hollow cylinder with a cylindrical inner surface (302), a cylindrical outer surface (304), and a ring-shaped side surface (306). The reel (300) is arranged to be rotatably connected with a shaft (308) of a reel receiver (118) of the roll-fed packaging machine (100). Further, the arrangement comprises a web (104) of packaging material rolled-up on the reel (300), wherein the web (104) comprises a number of sub-portions (310a, 310b) placed after one another, each sub-portion being arranged to be formed into a package (116). The ring-shaped side surface (306) is provided with a pattern (312) such that a rotational position of the reel (300) with respect to the reel receiver (118) can be determined by using a sensor (314) fixedly arranged on the reel receiver (118).