Wrapping Machine Film Deflector Retainer Mechanism
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Solution Overview
Problem
Film tends to leave the roll and fall off the bale during the wrapping process in existing film wrapping machines, leading to reduced tension and potential failure in securing the bale.
Innovation Solution
A retainer mechanism, such as a groove or hook, is integrated into the film deflector to prevent the film from slipping off, ensuring constant tension by adjusting to the bale's movement and maintaining contact with the film end, even as the bale rotates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the film is deflected by rolls to keep the film under tension during wrapping, then the film tension is maintained, but the film may still slip off the deflector or roll
Solution Approach 1:
A retainer element is introduced as an intermediary component between the deflector roll and the film end. This retainer acts as a mediator that physically blocks the film from slipping off the deflector while allowing the deflector to maintain its film-tensioning function. The retainer creates a mechanical interface that prevents the harmful effect (film slipping) without interfering with the useful function (tension maintenance).
Solution Approach 2:
The retainer element is positioned in advance to prevent the film from slipping off the deflector before it can cause problems. By placing this preventive barrier at the critical location where film slipping occurs, the system proactively counteracts the potential harmful effect rather than reacting to it after it happens.
2Productivity
If the first layer moves towards and away from the retained film end during bale rotation, then the wrapping process continues, but the varying distance causes film tension fluctuations
Solution Approach 1:
The retainer serves as a stable intermediary anchor point for the film end during bale rotation. While the bale rotates and the film layer moves toward and away from the film holder, the retainer maintains a consistent reference position on the deflector, providing a reliable anchor that minimizes tension fluctuations caused by the varying geometry during rotation.
3Device complexity
If a stationary deflector is used to keep the film tight, then the structure is simple, but the film may leave the roll and fall off the bale
Solution Approach 1:
The deflector system is segmented into two functional components: the deflector roll itself (which maintains film tension) and the retainer element (which prevents film slipping). This segmentation allows each component to perform its specific function optimally - the deflector for tension and the retainer for security - while together they provide a more reliable system than either component alone.
Solution Approach 2:
The retainer element is added as an intermediary component to the simple stationary deflector structure. This addition transforms the basic deflector from a tension-maintaining element into a dual-function system that also prevents film slipping, thereby improving reliability without significantly increasing overall structural complexity.
Data Source
Figure 1
Figure 2~3
AI summary
A wrapping machine (10) has a film dispense assembly (36) rotated on an orbit around an object (18) to be wrapped. At the beginning of a wrapping cycle an end of the film (24) is kept in a film holder (22) and a run of the film (24) passes a deflector (30) which is located between the film (24) and the object (18). When the object (18) and wrapping arms (16) start rotating, the first layer of film (24) moves towards the film holder (22) and looses tension thereby. In order to build up tension again, the film (24) is caught be the deflector (30) and captured by a retainer (38) against slipping off the deflector (30).