Rotating Ring Film Wrapping With Onboard Vacuum Tension Control
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Solution Overview
Problem
Existing machines for wrapping bundles with stretch film face issues with unequal tensioning due to geometric inconsistencies and require external vacuum pumps with complex connections and dynamic manifold systems, which cause load losses and operational inefficiencies.
Innovation Solution
A machine with a vacuum box integrated on a rotating ring, powered by a vacuum pump onboard and a dynamo, uses a magnetic transmission and a brake-clutch system to maintain tension control and continuous suction independent of the ring's rotation, eliminating the need for external vacuum pumps and complex connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If an external vacuum pump with dynamic manifold system is used, then tension control of the film is achieved, but device complexity and connection arrangements increase
Solution Approach 1:
The vacuum pump is integrated directly into the rotating ring structure, merging the vacuum generation function with the film dispensing mechanism. This eliminates the need for external vacuum pumps and dynamic manifold systems, reducing device complexity while maintaining tension control through the vacuum box that interfaces directly with the film
Solution Approach 2:
The rotating ring structure serves dual functions: it both dispenses the film and generates the vacuum suction needed for tension control. The vacuum pump mounted on the rotating ring provides self-contained vacuum generation, making the system self-sufficient and eliminating external dependencies
2Quantity of substance
If a dynamic manifold system is used for vacuum distribution, then vacuum is distributed through the system, but load losses increase
Solution Approach 1:
The dynamic manifold system is completely removed from the design. Instead of distributing vacuum through a complex manifold network, the vacuum pump is positioned to provide direct local suction at the film interface point, eliminating intermediate distribution components and associated energy losses
Solution Approach 2:
The vacuum box serves as a direct intermediary between the vacuum pump and the film, creating a simple, direct vacuum application path without the need for complex manifold intermediaries that cause load losses
3Ease of manufacture
If the vacuum pump is placed outside the wrapping ring, then connection arrangements are simplified, but operational efficiency decreases due to complex assembly
Solution Approach 1:
The vacuum pump is mounted directly on the rotating ring, merging the vacuum generation function with the wrapping mechanism. This integration improves operational efficiency by eliminating complex external connections and assembly requirements, while the compact mounting maintains ease of manufacture
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
Ensures consistent tensioning and continuous suction without external vacuum pumps, improving operational efficiency and reducing complexity and load losses.
Implementation Method 1
an additional tension control of the film is provided by the arrangement of a vacuum box the effect of which is a tensioning proportional to the absolute value of the vacuum for the surface of the box interfaced with the film
Implementation Method 2
powered by a vacuum pump onboard and a dynamo
Data Source
AI summary
A machine wrapping bundles with stretch film from a reel with continuous suction includes a ring wrapping machine arranging stretch film around the bundles. The film unwinds from a reel on a rotating ring of the wrapping machine to wrap around bundles, during the passing of the bundles. A pre-stretching group of the stretch film generates an axial deformation of the stretch film. A vacuum box downstream of the pre-stretching group continuously receives the deformed film. The pre-stretching group and vacuum box are arranged on the rotating ring around the bundles. A rotating magnetic track associated with the rotating ring causes a magnetic track wheel/disc to rotate, creating a magnetic transmission having a shaft supported in the pre-stretching group, which actuates a rubber roller on which the film passes. A dynamo connects directly to the magnetic transmission and batteries. A vacuum pump connects to the vacuum box and batteries.