Wrapping Machine Self-Calibration via Conveyor Encoder Feedback
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Solution Overview
Problem
Existing wrapping machines require manual input of tray size information by a service technician, which can lead to errors if not accurately entered, and lacks an automated calibration method that does not require a tray or user input.
Innovation Solution
A wrapping machine with a self-calibration process that uses a conveyor system and controller to determine the distance from a start position to a trayed item detection arrangement, storing this distance as a calibration value for future use, allowing the machine to automatically set wrap parameters without manual input.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If manual tray size input by service technician is used, then calibration can be performed, but human error is introduced and accuracy deteriorates
Solution Approach 1:
The system performs self-calibration by automatically measuring tray dimensions using sensors and encoders without requiring service technician intervention. The controller autonomously moves the conveyor, detects tray positions, calculates distances, and stores calibration values, enabling the system to calibrate itself while maintaining high accuracy and eliminating human error.
2Ease of operation
If manual calibration with tray placement is used, then tray size can be determined, but the process requires user input and increases operation complexity
Solution Approach 1:
The system replaces manual mechanical tray placement and measurement with an automated conveyor system controlled by a controller. The controller automatically moves the conveyor to specific positions, uses encoders to track movement, and calculates tray dimensions through coordinate geometry, eliminating the need for service technicians to physically handle trays and perform manual measurements.
3Reliability
If automated self-calibration is implemented, then human error is eliminated, but the system requires sophisticated control and measurement mechanisms
Solution Approach 1:
The system uses feedback from encoders mounted on the conveyor drive mechanism to continuously monitor the actual position of the conveyor during calibration. The controller receives encoder signals, compares actual positions with target positions, and uses this feedback to accurately calculate tray dimensions and store calibration values, ensuring high reliability while managing system complexity through closed-loop control.
Data Source
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AI summary
A wrapping machine for wrapping trayed items includes a wrap station and a conveying system for moving trayed items from an input station to the wrap station. The conveying system includes a conveyor for moving trayed items from the input station to a trayed item detection arrangement, and a prime mover operatively connected for moving the conveyor. A controller connected to the trayed item detection arrangement and the prime mover is configured for selectively carrying out a self-calibration operation in which: the prime mover is operated to cause movement of a portion of the conveyor from a start position to the trayed item detection arrangement; and an amount of prime mover movement required for the portion to travel from the start position to the trayed item detection arrangement is monitored and used to store a calibration value in memory of the controller.