Wrapping Machine Sensing Assembly for Load Containment Data

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Solution Overview

Problem

Current methods for determining the effectiveness of packaging materials in wrapping loads are inefficient and often inaccurate, leading to inadequate containment forces during shipping, which can result in damage, delays, and increased costs due to excessive material usage.

Innovation Solution

A wrapping machine equipped with sensing assemblies and a controller that measures packaging material length, weight, and layer distribution, providing real-time data on the display device to optimize wrapping parameters and ensure adequate containment force without excess material.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If manual measurement methods are used to generate wrapping data, then measurement precision can be achieved, but loss of time increases significantly

Engineering Contradiction:

Improvewrapping data accuracyVSAvoiddata generation time

Core Design Contradiction:

Measurement precisionVSLoss of time

Solution Approach 1:

The patent replaces manual mechanical measurement systems with an automated sensing assembly that uses sensors (optical, capacitive, or inductive) to detect packaging material characteristics. The controller processes sensor signals to automatically determine packaging material weight, eliminating the need for manual cutting and weighing operations while maintaining measurement accuracy.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The wrapping machine performs self-measurement by incorporating sensing assemblies that automatically detect and measure packaging material properties during the wrapping process itself. The system generates its own wrapping data without requiring external manual intervention, cutting packaging material, or separate weighing operations.

Inventive Principle:

Principle #25Self-service

2Measurement precision

If packaging material is cut off for analysis, then measurement precision improves, but loss of substance increases

Engineering Contradiction:

Improvepackaging material measurement accuracyVSAvoidpackaging material waste

Core Design Contradiction:

Measurement precisionVSLoss of substance

Solution Approach 1:

The patent replaces the mechanical cutting and physical weighing process with a sensing system that measures packaging material properties in-situ during wrapping. The sensing assembly detects material characteristics through non-contact or minimal-contact sensing, allowing accurate measurement without removing or cutting the packaging material from the load.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Measurement precision

If multiple test loads are wrapped to determine packaging effectiveness, then measurement precision improves, but productivity decreases

Engineering Contradiction:

Improvepackaging effectiveness data accuracyVSAvoidshipment rate

Core Design Contradiction:

Measurement precisionVSProductivity

Solution Approach 1:

The patent enables continuous data collection during normal wrapping operations by incorporating sensing assemblies into the wrapping machine. Wrapping data is generated for every load without interrupting the wrapping process or requiring separate test loads, maintaining both measurement accuracy and high productivity throughout production.

Inventive Principle:

Principle #20Continuity of useful action

Solution Approach 2:

The wrapping machine automatically generates its own wrapping data during routine operations, eliminating the need for dedicated test loads or separate measurement campaigns. Each load wrapped by the machine contributes to the dataset, allowing continuous improvement of packaging effectiveness knowledge without impacting production rates.

Inventive Principle:

Principle #25Self-service

4Reliability

If more packaging material is used to ensure adequate containment, then reliability improves, but loss of substance increases

Engineering Contradiction:

Improvecontainment force adequacyVSAvoidpackaging material usage

Core Design Contradiction:

ReliabilityVSLoss of substance

Solution Approach 1:

The patent implements feedback by measuring actual wrapping parameters (packaging material weight, length, layers) and using this data to adjust and optimize future wrapping operations. The controller analyzes wrapping data to determine the minimum effective packaging material requirements, enabling operators to use precisely the right amount of material needed for adequate containment rather than excessive amounts.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent changes the parameter of packaging material quantity from a fixed or conservative estimate to a dynamically optimized value based on measured wrapping data. By analyzing actual wrapping performance and containment effectiveness, the system adjusts packaging material usage parameters to achieve adequate containment with minimal material waste.

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS9493262B2Machine generated wrap data

Publication Date: 2016.11.15 LANTECH COM LLC

AI summary

A method for generating data with a wrapping machine during wrapping of a load includes measuring a length of packaging material dispensed during wrapping of the load with a sensing assembly on the wrapping machine. The method further includes obtaining a value indicative of a weight of the packaging material per unit of length and determining a weight of the packaging material dispensed on the wrapped load based on the measured length and the obtained value without removing the packaging material from the load. The determined weight of the packaging material is displayed on a display device.