Strap Tension Detection via Mechanical Impulse Response
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Solution Overview
Problem
Existing methods for producing strapped bundles, such as those used for beverage containers, often result in inconsistent strap tension, leading to bundles that are either too tight or too loose, making them unsuitable for sale and requiring frequent re-strapping, which is inefficient and costly.
Innovation Solution
A method and device that apply a mechanical impulse to the strapping to detect the strap tension using sensors like force, pressure, or acceleration sensors, allowing for real-time adjustment and quality control of the strap tension during the production and transport process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional strapping methods are used without real-time monitoring, then the production process is simple, but the strap tension consistency deteriorates leading to quality issues
Solution Approach 1:
The patent replaces complex mechanical tensioning systems with a mechanical impulse measurement system. Instead of using complex mechanical devices to maintain and monitor tension continuously, the invention applies simple mechanical impulses and measures the resulting vibrations to determine tension, thereby achieving high measurement precision with relatively simple device complexity.
Solution Approach 2:
The patent introduces vibration frequency as an intermediary parameter to indirectly measure strap tension. Rather than directly measuring the difficult-to-access tension force, the system uses the vibration frequency of the strap (which serves as an intermediary) to infer the tension level, enabling precise measurement without complex direct sensing mechanisms.
2Reliability
If strap tension is not monitored in real-time, then the production process is fast, but the quality control deteriorates requiring re-strapping
Solution Approach 1:
The patent performs preliminary quality control by measuring strap tension immediately after application using mechanical impulse. This preliminary measurement allows the system to detect and correct tension issues right at the point of application, preventing defective bundles from proceeding further in the production process and eliminating the need for re-strapping later.
Solution Approach 2:
The patent implements feedback control by continuously monitoring strap tension through mechanical impulse measurements and using this information to adjust the strapping process in real-time. The measurement results feed back to the control system, which can immediately correct deviations, ensuring consistent quality without slowing down production.
3Measurement precision
If mechanical impulse measurement is implemented, then the strap tension can be detected, but the device complexity increases
Solution Approach 1:
The patent uses simple mechanical impulse generation (such as a hammer or impactor) and basic vibration sensors instead of complex electronic or optical measurement systems. By substituting sophisticated measurement technology with simple mechanical means, the system achieves adequate measurement precision while keeping device complexity low.
Solution Approach 2:
The patent employs simple, inexpensive mechanical impulse generators and basic sensors that can be easily replaced if needed. Rather than investing in complex, expensive measurement equipment, the system uses simple mechanical components that provide sufficient measurement accuracy for the application, reducing overall system complexity and cost.
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 quick and reliable adjustment of strap tension, ensuring that strapped bundles meet quality standards, reducing waste and operational costs by allowing for continuous monitoring and separation of improperly tensioned bundles during transport.
Implementation Method 1
the strap tension of the at least one strap of the strapping is determined by detecting an impulse response of a mechanical impulse applied to the strap
Implementation Method 2
an impulse being applied by a mechanically acting ram, clapper, hammer or the like
Data Source
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AI summary
A method and a device (66) for manufacturing a strapped bundle (10) are disclosed. In this method, at least two articles (12) or containers (14) are held together and connected by at least one horizontally stretched, band- or strip-like, closed strapping (18) around their respective outer surfaces. The strapping (18) is formed by one, two, or more identical or different strapping bands (20) made of plastic or a composite material, the ends of which are fixed to one another by applying a definable band tension (32). The band tension (32) of the at least one strapping band (20) of the strapping (18) is then detected by sensing the impulse response of a mechanical impulse (p) applied to the strapping band (20). The invention further comprises a measuring arrangement (30) for detecting the band tension (32) of such strapped bundles (10).The measuring arrangement (30) includes a device (34) for applying a mechanical impulse (p) to at least one strapping band (20) of the strapping (18) and a device (36) for recording an impulse response to the mechanical impulse (p).