Compact Strapping Device with Planetary Gear and Brushless Motor
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Solution Overview
Problem
Existing mobile strapping devices for packaging goods are heavy, voluminous, and top-heavy due to numerous components and motors, leading to high maintenance costs and reduced functional reliability, while automation complicates ergonomic handling and energy efficiency.
Innovation Solution
A mobile strapping device equipped with a planetary gear system and a brushless direct current motor for efficient energy use, allowing for compact design, high torque production, and controlled tensioning and welding processes, along with a lithium-ion battery for reliable energy supply and a toggle lever system for enhanced reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If automated processes with numerous components are used, then productivity is improved, but device complexity and weight increase
Solution Approach 1:
The patent combines multiple functions (tensioning, friction welding, and oscillating movement) into a single integrated device. The friction welder includes both the oscillating movement mechanism and the welding element in one unit, eliminating the need for separate tensioning devices and reducing overall component count while maintaining automated operation.
Solution Approach 2:
The friction welder is designed as a multi-functional component that performs both the oscillating movement for welding and the tensioning function. The single drive unit powers multiple operations including the oscillating friction welding process, the oscillating movement of the welding element, and the tensioning of the strap, thereby reducing device complexity.
2Productivity
If numerous components are used for automated processes, then productivity is improved, but the device becomes top-heavy and handling properties deteriorate
Solution Approach 1:
The device is divided into functionally independent but compact modules: the friction welder unit with integrated oscillating mechanism, the tensioning mechanism, and the control unit. This segmentation allows for a more balanced weight distribution and compact overall structure that is easier to handle while maintaining automated functionality.
Solution Approach 2:
By merging the oscillating movement mechanism and welding element into a single friction welder unit, the patent reduces the number of separate heavy components. This integration consolidates weight into a more manageable configuration that improves handling properties while preserving automated operation.
3Device complexity
If a common drive is used for tensioning and friction welding, then device complexity is reduced, but the drive must handle variable speed and torque requirements
Solution Approach 1:
The patent employs a dynamic control system that adjusts the drive parameters in real-time. The control unit modifies the speed and torque of the common drive during operation to match the varying requirements of tensioning and friction welding processes, enabling a single drive to handle multiple operations with different mechanical characteristics.
Solution Approach 2:
The drive system utilizes variable parameter control, where the control unit dynamically changes speed, torque, and other operational parameters based on the current process requirements. This allows the same drive unit to efficiently perform both tensioning and friction welding operations by adjusting its output characteristics as needed.
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 solution results in a compact, reliable, and ergonomic strapping device that can handle sensitive goods with reduced risk of damage, offering high-quality strapping with minimal operator effort and extended battery life, ensuring consistent performance and reduced maintenance needs.
Implementation Method 1
a friction shoe moving in an oscillating manner is pressed onto the area of two ends of the strap loop. The pressure and the heat produced by the movement briefly locally melt the strap
Implementation Method 2
In order to be able to make the strapping device as compact as possible despite the high torque, a planetary gear system can also be arranged in the drive train of the strapping device
Implementation Method 3
a lithium-ion battery for energy storage, allowing for compact design, high torque production, and ergonomic handling
Data Source
AI summary
A strapping device including a tensioner operable to apply a strap tension to a loop of wrapping strap, a friction welder operable to produce a friction weld connection at two areas of the loop of wrapping strap disposed one on top of the other, a motor operable in a first rotational direction to drive the tensioner and in a second opposite rotational direction to drive the friction welder, and a control device. The control device is configured to, in response to receiving a first designated input: (1) operate the motor in the first rotational direction to drive the tensioner until a predetermined strap tension is reached in the loop of wrapping strap; and (2) afterwards, automatically operate the motor in the second different rotational direction to drive the friction welder to produce the friction weld connection.