Void Fill Machine Pivotable Crush Wheels Jam Prevention
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing paper conversion machines for producing void fill material face safety concerns due to crush wheel design and operation, and are prone to paper jams, which hinder efficient production of higher-density void fill material.
Innovation Solution
A machine design featuring an internal drive assembly with pivotable crush wheels and a unique inlet chute configuration that reduces paper jams by allowing the crush wheels to move apart in case of a jam, ensuring safe operation and efficient production of three-dimensional void fill material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If crush wheels are used to convert paper web into void fill material, then void fill material production is achieved, but safety concerns arise for operators
Solution Approach 1:
The machine is divided into separate functional sections with distinct access points. The inlet chute assembly can be opened independently from the crush wheel assembly, allowing operators to access and clear paper jams at the inlet without exposing themselves to the rotating crush wheels. This segmentation isolates hazardous components from operator access zones.
Solution Approach 2:
A movable divider or gate mechanism acts as an intermediary barrier between the operator and the crush wheels. This intermediate structure can be positioned to block access to the crush wheel area while allowing the inlet chute to remain accessible for paper loading and jam clearance, thereby mediating between operational needs and safety requirements.
2Productivity
If crush wheels and severing mechanisms are used to produce desired lengths, then void fill material is produced, but ongoing safety concerns persist in design and operation
Solution Approach 1:
The inlet chute assembly incorporates movable or adjustable components rather than fixed rigid structures. The inlet chute can be opened, closed, or repositioned dynamically based on operational requirements, allowing the machine to adapt its configuration for safety or maintenance without requiring complete disassembly or complex mechanical systems.
3Manufacturing precision
If paper web is pulled through crush wheels to form dense material, then void fill material is produced, but paper jams occur at crush wheels and outlet
Solution Approach 1:
The paper processing path is divided into separate accessible sections. The inlet chute assembly can be opened independently to access and clear paper jams before they propagate to the crush wheels or outlet. This segmentation allows for localized intervention to prevent jams from affecting the entire system.
Solution Approach 2:
The inlet chute is designed with features that prepare and guide the paper web before it enters the crush zone. The tapered configuration and guiding surfaces pre-position the paper correctly, reducing the likelihood of misalignment-induced jams at the crush wheels or outlet.
4Manufacturing precision
If inlet chute spacing is reduced to increase material density, then higher-density void fill is produced, but paper jams are more likely to occur
Solution Approach 1:
The inlet chute incorporates movable walls or adjustable spacing mechanisms that allow the chute configuration to be modified based on operating conditions. When paper jams are detected or anticipated, the chute spacing can be dynamically adjusted to a more open configuration to facilitate easier paper feeding and reduce jam probability, then returned to the tighter configuration for high-density production when operating normally.
Data Source
AI summary
A machine for converting sheet stock material into void fill material comprises an improved, angled inlet chute, an outlet chute, and an internal drive assembly comprising a motor and power transmission system for rotating a plurality of opposed crush wheels that pull the sheet stock from the inlet chute and push the void fill material to the outlet chute in a downstream direction. The internal drive assembly comprises a frame securing a motor and a first power transmission set to rotate a drive axle and a first set of crush wheels. The assembly comprises a subframe securing a driven axle and a second set of crush wheels that are rotated by a second power transmission set. The subframe is pivotably attached to the frame at a pivot point that allows the driven axle to pivot away from the drive axle at least partly in upstream and downstream directions.