Stretch Wrapping Load Profiling for Consistent Containment Force
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Solution Overview
Problem
Conventional wrapping machines face challenges in ensuring consistent and adequate containment force during load wrapping, particularly with non-standard loads, leading to potential product damage and material inefficiency, due to operator variability and load irregularities.
Innovation Solution
Implementing automatic load profiling to determine density parameters, using sensors to assess load stability and adjust control parameters such as wrap force and layer thickness, to optimize wrapping operations for loads with non-standard top layers, inboard portions, or irregular topographies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional manual control parameters are used for wrapping, then operator flexibility is maintained, but containment force consistency deteriorates due to operator variability and lack of knowledge
Solution Approach 1:
The system performs automatic load profiling and self-adjusts wrapping parameters based on sensed load characteristics. The machine independently determines density parameters, identifies non-standard loads, and modifies wrap force and layer distribution without operator intervention, enabling the system to serve itself and eliminate operator variability.
Solution Approach 2:
The patent replaces manual operator control with an automated sensing and control system. Sensors detect load properties and the controller automatically adjusts wrapping parameters, substituting human decision-making with mechanical-electronic systems that provide consistent, repeatable control based on actual load conditions.
2Reliability
If thicker and stronger packaging material is used to ensure adequate containment force, then load stability is improved, but material cost and weight increase
Solution Approach 1:
The system applies packaging material with locally optimized characteristics based on sensed load properties. By determining density parameters and identifying specific load regions, the controller adjusts wrap force and layer distribution to provide adequate containment only where needed, rather than uniformly across the entire load, thereby reducing overall material usage while maintaining stability.
Solution Approach 2:
The patent dynamically changes wrapping parameters including wrap force, layer distribution, and material application rate based on sensed load characteristics. This allows the system to optimize containment force for each specific load configuration, using minimum necessary material while achieving required stability.
3Adaptability or versatility
If manual control parameters are adjusted to accommodate non-standard loads, then adaptability is improved, but wrapping precision deteriorates due to operator inexperience
Solution Approach 1:
The system uses sensors to continuously monitor load characteristics and provides feedback to the controller, which automatically adjusts wrapping parameters. This closed-loop control ensures that non-standard loads are handled with precision by relying on actual sensed data rather than operator judgment, maintaining both adaptability and wrapping uniformity.
Solution Approach 2:
The machine independently profiles each load and self-adjusts wrapping parameters based on detected characteristics. This eliminates the need for operator knowledge or experience while maintaining adaptability to various load types, as the system automatically determines the appropriate wrapping strategy for each specific load configuration.
4Reliability
If wrap force is increased to ensure adequate containment, then containment force is improved, but product damage risk increases due to excessive force on sensitive products
Solution Approach 1:
The system applies different wrap forces to different regions of the load based on sensed characteristics and identified product sensitivity. By localizing high containment force to areas requiring it while using gentler forces on sensitive products, the system achieves adequate overall containment without causing damage to vulnerable items.
Solution Approach 2:
The patent dynamically adjusts wrap force parameters based on real-time sensing of load characteristics and product response. This allows the system to optimize containment force for each specific load configuration, applying minimum necessary force to prevent product damage while achieving required containment.
Data Source
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AI summary
The invention relates to a method of controlling a load wrapping apparatus of the type configured to wrap a load on a load support with packaging material dispensed from a packaging material dispenser through relative rotation between the packaging material dispenser and the load support, the method comprising determining a density parameter for the load prior to wrapping the load; and controlling one or more control parameters for the load wrapping apparatus when wrapping the load based upon the determined density parameter for the load