Variable Accumulator Dunnage System
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Solution Overview
Problem
Existing dunnage systems face challenges in efficiently accumulating and managing crumpled dunnage materials, leading to inefficiencies in storage and retrieval, as they often lack adaptive mechanisms to accommodate varying amounts of dunnage and prevent escape during the accumulation process.
Innovation Solution
A dunnage accumulator system with pivotally associated holding portions and a sensor to detect full conditions, allowing for adjustable accumulation space and preventing dunnage escape, integrated with a dunnage machine that produces crumpled dunnage and delivers it into the accumulator.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a fixed accumulation space is used, then the device structure is simple, but it cannot accommodate varying amounts of dunnage and may cause overflow
Solution Approach 1:
The accumulator employs movable holding portions that can dynamically adjust the accumulation space volume. The holding portions are capable of moving relative to each other along guide rails, allowing the system to adapt the accumulation space to varying dunnage volumes while maintaining structural integrity through guided motion mechanisms.
Solution Approach 2:
The accumulator structure implements a nested arrangement where multiple holding portions are positioned within a common housing. The holding portions can be nested together when the accumulation space is small and can be extended outward when more space is needed, creating a compact yet adaptable structure that efficiently uses available space.
2Productivity
If dunnage is continuously fed into the accumulator, then productivity is high, but dunnage may escape from the accumulator
Solution Approach 1:
The accumulator incorporates a sensor system that continuously monitors the accumulation space for full conditions. When the sensor detects that the accumulation space has reached its capacity, it sends a signal to interrupt the dunnage production process, creating a closed-loop feedback control system that prevents overflow while maintaining high productivity during normal operation.
Solution Approach 2:
The arcuate-shaped second holding portion is positioned and configured to preemptively prevent dunnage escape before it can occur. The curved geometry creates a containment barrier that guides dunnage material and prevents it from being pushed out by additional incoming dunnage, addressing the containment issue before overflow can happen.
3Quantity of substance
If the accumulation space is increased to accommodate more dunnage, then storage capacity is improved, but the device occupies more space
Solution Approach 1:
The accumulator utilizes vertical space by positioning holding portions at different heights within the housing. The first holding portion is disposed below the accumulation space while the second holding portion is positioned above, creating a three-dimensional accumulation volume that maximizes storage capacity without proportionally increasing the horizontal footprint of the device.
Solution Approach 2:
The movable holding portions allow the accumulation space to expand and contract as needed. When dunnage storage capacity needs to be increased, the holding portions move to expand the volume. When less space is needed, the holding portions retract, reducing the effective footprint and allowing the same physical space to serve multiple operational requirements.
Data Source
AI summary
A dunnage handler for controlling the outfeed of dunnage from a dunnage machine is disclosed and can include a dunnage accumulator with first and second holding portions configured and associated with each other to define a dunnage accumulation space therebetween and for receiving and removably retaining the dunnage in the accumulation space from a dunnage machine and an articulation associating the first and second holding portions such that the holding portions are movable with respect to each other to vary the accumulation space to accommodate a varying amount of dunnage held therein, where a sensor and controller can be included to stop dunnage production when the accumulator is full.