Variable Speed Control for Waste-Free Strap Bundling
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Solution Overview
Problem
Existing bundling tools for waste-free bundling of bundling goods using endless straps face inefficiencies in speed and reliability due to the strap being pushed at full speed, leading to potential lateral breakout and errors, as the control unit requires time to reverse the motor direction, resulting in unnecessary strap length usage.
Innovation Solution
The bundling tool employs a control unit that sets a higher pushing speed for the first path portion of the strap's path and a lower speed for the second path portion, where the strap is retracted and tightened, with the ability to calibrate these speeds automatically based on jaw unit size, ensuring reliable and efficient bundling by optimizing the path lengths and motor control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the strap is pushed at full speed through the lock element, then the bundling speed is improved, but the reliability deteriorates due to potential lateral breakout and errors
Solution Approach 1:
The patent applies dynamics by making the pushing speed variable rather than constant. The control unit adjusts the motor speed dynamically based on the strap's position in the path: higher speed in the first path portion and lower speed in the second path portion. This dynamic speed adjustment resolves the contradiction by allowing high productivity when possible while ensuring reliability during critical phases like retraction and tightening.
2Loss of time
If the control unit reverses motor direction quickly, then the bundling time is reduced, but the strap is pushed further than necessary causing waste
Solution Approach 1:
The patent applies preliminary action by pre-defining the path portions and their corresponding speed ranges in the control unit. The first path portion (higher speed) and second path portion (lower speed) are predetermined, allowing the control unit to switch speeds proactively based on position rather than reactively after overshooting. This resolves the contradiction by balancing quick direction reversal with precise strap positioning to minimize waste.
3Loss of time
If the strap is pushed further through the lock element, then the control unit has time to reverse direction, but the jaw claws and system must guide the sliver reliably to exclude lateral breakout
Solution Approach 1:
The patent resolves this contradiction through dynamic speed adjustment. During the first path portion, higher speed is used to minimize time loss. When entering the second path portion (where the strap is retracted back into the lock element), the speed is reduced to ensure reliable guiding and prevent lateral breakout. This dynamic approach allows sufficient time for direction reversal while maintaining guiding reliability during critical phases.
4Device complexity
If a single pushing speed is used for the entire path, then the device complexity is reduced, but the bundling efficiency and reliability are compromised
Solution Approach 1:
The patent implements a dynamic control system that adjusts pushing speed based on the strap's position in the path. The control unit receives position information and automatically selects appropriate speed ranges (higher for the first path portion, lower for the second path portion). This resolves the contradiction by introducing manageable complexity that significantly improves bundling efficiency and reliability compared to a single fixed speed approach.
Data Source
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AI summary
The disclosure relates to a bundling tool (1) for waste-free bundling of a bundling good (4) by means of an endless strap (3), comprising an exchangeable jaw unit (2) for guiding an end section (3a) of the endless strap (3) around the bundling good (4), a lock feeding unit (5) for providing a lock element (15) for the endless strap (3), with a pushing and pulling unit (6) for pushing the end section (3a) of the endless strap (3) by means of a motor along a path (7) through the provided lock element (15) as well as along the jaw unit (2), with the bundling good (4) gripped by the jaw unit (2) thus around the bundling good (4) and back into the lock element (15) provided, as well as for the subsequent retraction of the end section (3a) of the endless strap (3), with a sensor unit (8) for detecting the end section (3a) pushed back into the lock element (15), with a cutting unit (9) for separating the end section (3a) arranged around the bundling good (4) from a remaining section (3c) of the endless strap (3) remaining in the bundling tool (1), as well as with a control unit (10), which is arranged in a normal operating mode, for a first path portion (7a) of the path (7) for the pushing and pulling unit (6) during pushing, to preset a greater advance speed of the end section (3a) than for a second path portion (7b) following the first path portion (7a) wherein the second path portion (7b) comprises the part of the path (7) extending back into the lock element (15) in order to provide an improved bundling tool (1) for waste-free bundling of a bundling good (4), in particular a more reliable, faster and easier-to-operate bundling tool (1).