Tape Head Two-Stage Spring Tensioning
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Solution Overview
Problem
Conventional tape heads for sealing cases on conveyor systems require high force to tension the spring for applying tape, which can lead to deformation of the case and inefficient energy use, as energy is typically stored in a single stage.
Innovation Solution
A two-stage energy capture system that tensions a spring by first pivoting a first application roller and then further tensioning it with a lever or other structure, allowing the stored energy to move a second application roller around the case to press the tape against the trailing side, reducing the force needed at any given time and minimizing case deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If high force is applied to tension the spring for applying tape, then tape application effectiveness is improved, but case deformation increases and energy efficiency decreases
Solution Approach 1:
The spring tensioning process is divided into two distinct stages: first stage where the application roller pivots and tensions the spring partially, and second stage where a lever mechanism further tensions the spring. This segmentation allows the spring to be tensioned gradually rather than all at once, reducing peak forces that could deform the case while still achieving sufficient tension for effective tape application.
Solution Approach 2:
The first application roller performs a preliminary action by pivoting and partially tensioning the spring before the second stage lever mechanism engages. This preliminary tensioning prepares the spring for further tensioning in the second stage, allowing the system to build up the required spring tension progressively rather than applying maximum force immediately, thereby minimizing case deformation.
2Force
If high force is applied to tension the spring for applying tape, then tape application effectiveness is improved, but energy efficiency deteriorates
Solution Approach 1:
The energy storage process is segmented into two stages corresponding to the two-stage spring tensioning. The first stage captures energy during roller pivoting, and the second stage captures additional energy during lever operation. This segmentation allows the system to capture and store energy more efficiently by utilizing the motion of components throughout the entire sealing process rather than relying on a single high-force moment.
Solution Approach 2:
The spring tensioning process continues through both stages without interruption, with the spring being progressively tensioned as the sealing process unfolds. This continuous action ensures that energy is captured and stored throughout the entire sequence of operations, improving overall energy efficiency by eliminating wasted energy from single-stage tensioning.
3Device complexity
If a single-stage spring tensioning system is used, then device complexity is reduced, but the force required and case deformation increase
Solution Approach 1:
The tensioning system is segmented into two functional stages: the first stage utilizes the pivoting motion of the application roller itself to tension the spring, while the second stage introduces a lever mechanism that provides additional tensioning. This segmentation allows the system to achieve higher forces without requiring a single complex high-force mechanism, distributing the force application across multiple simpler stages.
Solution Approach 2:
The system employs dynamic elements including a pivoting application roller and a lever mechanism that engage at different stages of the sealing process. These dynamic components allow the spring tension to be adjusted progressively based on the motion of the case and rollers, enabling the system to generate higher forces when needed while maintaining lower forces during other phases, thus reducing overall device complexity requirements.
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
This approach reduces the pressure applied to the case, minimizing deformation and allowing for efficient energy storage and use, enabling effective sealing of cases without excessive force or deformation.
Implementation Method 1
a spring is tensioned when a case, moving relative to the tape head (e.g., the case may be moving along a conveyor), contacts a first application roller
Implementation Method 2
as the first application roller pivots in response to contact a leading sidewall of the case, a spring is tensioned
Data Source
AI summary
A tape head includes a two-stage system by which a spring is tensioned. In a first stage, the spring may be partially tensioned when a case, moving along a conveyor, contacts a first application roller. The spring may be additionally tensioned when the case, continuing to move along the conveyor, contacts the second stage. In one example of the second stage, a lever is moved by contact with the moving case. Movement of the lever moves tensions the spring further. By tensioning the spring in multiple stages, assemblies and/or processes, less force is applied by the case to the first application roller. Accordingly, it is less likely to deform the case. The tensioned spring provides energy to move a second application roller around a trailing edge of the case, and thereby press a cut end of the tape against a side of the case.