Self-Propelled Wrapping Machine Obstacle Scanning and Auto Restart
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Solution Overview
Problem
Existing self-propelled wrapping machines lack effective protection against obstacles, particularly the feeler element, and require manual intervention for restart after an emergency stop, leading to prolonged downtime.
Innovation Solution
Incorporation of a scanning device to detect obstacles in defined areas, a control unit to manage automatic stops and restarts, and sensors to ensure safe operation, allowing for immediate stops and simplified restarts without operator intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a bumper is added to protect against obstacles, then safety is improved, but the feeler element remains unprotected and collision detection is delayed
Solution Approach 1:
The protective system is segmented into multiple independent sensing zones: the bumper provides rear protection while the feeler element with its own sensor provides lateral protection. This segmentation allows each component to detect collisions in its specific zone, enabling the feeler element to detect obstacles independently without waiting for the bumper to engage.
Solution Approach 2:
The feeler element's sensor performs preliminary collision detection before the main bumper would be engaged. By positioning the feeler element laterally and equipping it with an independent sensor, the system detects obstacles in advance of a potential impact with the main body, allowing earlier emergency stopping and reducing downtime.
2Ease of operation
If manual reset procedure is used after emergency stop, then control simplicity is maintained, but operational efficiency decreases due to operator intervention requirement
Solution Approach 1:
The control system performs self-service by automatically resetting itself after an emergency stop. The sensor detects when the obstacle has been removed, and the control unit automatically resumes operation without requiring manual intervention. This maintains control simplicity while dramatically improving productivity by eliminating operator wait time.
Solution Approach 2:
The sensor provides continuous feedback to the control unit about the presence of obstacles. When the obstacle is removed, the sensor signal changes, triggering the control unit to automatically restart the wrapping operation. This feedback mechanism enables automatic recovery while keeping the control system simple and intuitive.
3Manufacturing precision
If feeler element extends laterally to follow load profile, then wrapping precision is improved, but collision risk with obstacles increases
Solution Approach 1:
The feeler element acts as an intermediary between the main carriage and the load. It extends laterally to follow the load profile for precise wrapping while being equipped with its own sensor to detect obstacles. This intermediary structure allows the main carriage to maintain a safer distance while the feeler element performs the precise following function with enhanced collision awareness.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enables the self-propelled wrapping machine to safely avoid collisions with obstacles, automate restarts, and reduce downtime by detecting and responding to potential hazards quickly, enhancing operational efficiency.
Implementation Method 1
The external walls of the bumper are flexible and elastically deformable so as to absorb the impact, i.e., the kinetic energy resulting from a collision
Implementation Method 2
at least one scanning device (30) configured to scan a defined area (A, B) of the supporting plane (P) in order to detect a possible obstacle in said area (A, B) and send, in presence of the obstacle, an obstacle alarm signal (ALL1)
Data Source
AI summary
A self-propelled wrapping machine movable on a supporting plane to wrap a load with a film has a self-propelled carriage provided with a drive wheel, an upright slidably supporting an unwinding unit provided with a reel of film, an actuator to operate the drive wheel and the unwinding unit along the upright, a control unit to control the actuator, and a scanning device to scan a defined area of the supporting plane to detect a possible obstacle in the area and in the presence of the obstacle to send an obstacle alarm signal to the control unit to stop the actuator. The scanning device is configured to scan a first area of the supporting plane during a wrapping cycle of a load and a second area during a manual maneuvering procedure, the second area being smaller than the first area.