Challenge
On a client packaging company’s wrapping machine, a small tail of film remained after the cutting process that needed to be wrapped around the finished roll to ensure a clean and secure product. The main challenge was to rotate the output mandrel to complete this wrapping without adding new actuators, due to mechanical and system limitations within the existing machine.
Solution
A flipped-belt mechanism was designed to intermittently engage with the mandrel at specific moments in the cycle, allowing it to rotate just enough to wrap the remaining film tail around the roll.
A second mechanism was introduced to gently push the film toward the roll to help the tail adhere properly. Instead of adding another actuator, the design utilized an existing rotary motion that previously provided only 15° of movement. By implementing a handle connected through two sprockets and a chain, the angular motion was amplified, enabling enough displacement to move a brush that presses the film against the roll surface.
Result
The final design successfully wrapped the film tail using only the machine’s existing motions, eliminating the need for additional actuators. This solution improved the cleanliness of the finished rolls while maintaining system simplicity and reliability.
