Challenge
Our client requested the design of a mechanism for their packaging machine to wind up the film tail after the cutting process. The machine operates with three mandrels mounted on a rotating hub. After each winding process, the film is automatically cut, the hub rotates, and the next mandrel begins the winding cycle. However, the cutting process leaves a relatively long film tail that must be wrapped around the finished roll. Since the roll circumference varies between products, the tail length also changes, requiring a flexible and reliable solution.
Solution
A mechanism was designed using three sprockets mounted on the three mandrels and a chain system that engages with the target mandrel during each cycle. The chain is temporarily engaged to rotate the mandrel and wrap the film tail around the roll, then disengages before the next cycle begins. The engagement and disengagement of the chain are controlled pneumatically, while a stepper motor drives the chain rotation. Both the pneumatic system and the stepper motor are controlled through the machine’s main PLC.
Result
The final system reliably wraps the remaining film tail around rolls of different sizes while integrating seamlessly with the machine’s existing cycle. The mechanism provides consistent product finishing and automated operation without interfering with the hub’s multi-mandrel workflow.
