Wrapping Machine Containment Force Measurement

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Solution Overview

Problem

Current methods for wrapping loads with packaging material lack effective measurement and analysis of containment force, leading to inefficiencies and potential failures during transport due to inadequate wrapping, excessive material usage, and variability in packaging materials and operator settings.

Innovation Solution

A wrapping machine with a sensing assembly that determines relative revolutions and dispenser height to calculate the number of layers and containment force applied, displaying data on a graphical interface to ensure adequate wrapping and minimize film breaks, thereby optimizing packaging material usage and ensuring minimum containment force standards are met.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If packaging material is applied with more layers to increase containment force, then the reliability of load containment is improved, but the weight and cost of packaging material increases

Engineering Contradiction:

Improvecontainment forceVSAvoidpackaging material weight

Core Design Contradiction:

ReliabilityVSWeight of stationary object

Solution Approach 1:

The system changes parameters by measuring actual wrap characteristics (layers, tension, coverage) and adjusting wrapping parameters in real-time to achieve optimal containment force with minimal material. The controller modifies wrapping parameters based on measured data to prevent both under-wrapping and over-wrapping.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The system implements feedback by using sensors to measure wrap characteristics and feeding this information back to the controller, which then adjusts the wrapping process. This closed-loop control ensures that the minimum required containment force is achieved without excessive material usage.

Inventive Principle:

Principle #23Feedback

2Measurement precision

If manual measurement and analysis of containment force is performed, then the measurement precision of wrapping quality is improved, but the time and effort required increases

Engineering Contradiction:

Improvewrapping quality measurementVSAvoiddata generation and analysis time

Core Design Contradiction:

Measurement precisionVSLoss of time

Solution Approach 1:

The system replaces manual mechanical measurement methods with automated electronic sensing and digital analysis. Sensors mounted on the wrapping machine automatically measure wrap characteristics, and a controller performs real-time analysis, eliminating the need for manual measurement and significantly reducing time and effort.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The wrapping machine performs self-measurement and self-analysis of wrap quality through integrated sensors and controllers. The system automatically monitors its own wrapping process, measures containment force characteristics, and adjusts parameters without external intervention, saving time and effort.

Inventive Principle:

Principle #25Self-service

3Measurement precision

If packaging material is cut from every wrapped load for analysis, then the measurement precision of material effectiveness is improved, but the loss of substance increases

Engineering Contradiction:

Improvematerial effectiveness measurementVSAvoidpackaging material waste

Core Design Contradiction:

Measurement precisionVSLoss of substance

Solution Approach 1:

The system replaces physical cutting and laboratory analysis with electronic sensing and digital measurement. Sensors mounted on the wrapping machine measure wrap characteristics in real-time during the wrapping process, eliminating the need to cut material from loads and preventing any additional waste.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system performs measurement and analysis during the wrapping process itself, before the load leaves the machine. By measuring wrap characteristics in real-time as the material is applied, the system eliminates the need for subsequent cutting and analysis, preventing material waste.

Inventive Principle:

Principle #10Preliminary action

4Productivity

If assumptions are made about consistency of wrapping quality across loads, then the productivity increases, but the reliability of containment force decreases

Engineering Contradiction:

Improvewrapping operation speedVSAvoidcontainment force consistency

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The system uses feedback from sensors to continuously monitor wrap quality across different loads and adjusts parameters in real-time. This ensures that each load receives the appropriate amount of containment force based on its specific characteristics, maintaining reliability while preserving productivity through automated control.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The system dynamically changes wrapping parameters based on measured load characteristics and wrap conditions. By adjusting parameters in real-time for each load rather than using fixed assumptions, the system maintains consistent containment force quality across varying loads without sacrificing productivity.

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS9488557B2Machine generated wrap data

Publication Date: 2016.11.08 LANTECH COM LLC

AI summary

Various methods are provided for determining and displaying wrapping data generated by a wrapping machine during wrapping of a load with a packaging material, e.g., to determine numbers of layers of packaging material applied to a load, a containment force applied to a load, and/or whether a load meets a predetermined minimum required containment force standard for the load.