Tape Applicator Dancer Arm Nip Roll Alignment
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Solution Overview
Problem
Existing commercial machines lack the capability to automatically apply closure tapes from a supply roll to a case at high speed while ensuring smooth tape feeding and proper alignment, especially when the tape is folded along the feed path.
Innovation Solution
A commercial tape applicator with a dancer arm and nip roll system that biases the nip roll onto the tape roll's periphery, a folding station to fold the tape's side edge onto the adhesive side, and guide mechanisms to align and stabilize the tape path, ensuring proper feeding and application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a commercial machine applies tape from a supply roll at high speed, then productivity is improved, but tape feeding smoothness and alignment deteriorate due to roll deformation
Solution Approach 1:
A dancer arm mechanism is introduced as an intermediary between the supply roll and the tape path. The dancer arm with its platform and nip roll creates a buffer zone that absorbs roll deformation and maintains consistent tape tension, ensuring smooth feeding despite high-speed operation and roll imperfections
Solution Approach 2:
The system dynamically adjusts tape tension and positioning parameters through the dancer arm's movable platform. By allowing the platform to shift position on the dancer arm, the system automatically compensates for variations in tape feed rate and roll deformation, maintaining optimal feeding conditions at high speeds
2Ease of operation
If a folding station is added to fold the tape edge, then the gripping area is provided, but device complexity increases
Solution Approach 1:
The folding station is integrated into the existing tape application mechanism by mounting it on the dancer platform. The folding components (guides, pressure rollers) are combined with the tape path structure, creating a multi-functional unit that both feeds tape and creates the folded edge grip without requiring separate independent mechanisms
Solution Approach 2:
The tape edge is folded over onto itself before the tape is applied to the carton. This preliminary folding action creates the non-stuck gripping area in advance, allowing the main applicator mechanism to focus on application while the folding preparation is already complete
3Manufacturing precision
If guide means are added to align the tape path, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
Guide means including flanges and alignment guides are positioned at strategic intermediary points along the tape path. These guides subtly steer the tape without requiring major structural changes, using simple geometric features to correct alignment deviations caused by roll deformation
Solution Approach 2:
The guide means utilize the tape's own physical properties and the existing machine structure to achieve alignment. The flanges on the dancer platform and guide rollers work passively with the tape tension and direction, automatically correcting alignment without active control systems or complex mechanisms
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 enables efficient, high-speed automatic application of folded tapes to cases, maintaining smooth tape feeding and alignment, even when the tape roll is deformed, improving the functionality of commercial machines.
Implementation Method 1
means biasing said dancer arm to press said nip roll onto a periphery of said tape roll
Implementation Method 2
to fold at least one side edge of said tape onto an adjacent adhesive side of said tape to form a folded edge on said tape
Data Source
AI summary
A commercial tape applicator capable of folding at least one side edge of a tape as it is fed to the applicator to provide an easily a gripped edge on the tape after it has been applied to the case. The invention provides a folding station on a dancer platform mounted on a dancer arm that has a nip roll at its free end and the arm is biased so that the nip roll is in contact with the periphery of a tape roll forming the source of tape and is usable to align the tape path through the folding station with the tape leaving the tape roll and accommodate deformation of the roll. A latch and cooperating cog wheel may be used to control the off feeding of the tape for the supply roll.