Project Objective
The objective of this project was to develop an innovative mechanical solution capable of securely holding plastic film on a rotating mandrel for approximately 10 seconds, enabling the wrapping system to initiate the wrapping cycle reliably. Previously, this task was performed manually by the operator, who was required to stop the machine and physically push the film between the mandrels at the start of each wrapping cycle. The goal was to eliminate manual intervention, reduce downtime, and improve operational consistency and efficiency.
Scope & Execution
A dedicated assembly was designed to fulfill this requirement. During the testing phase, multiple metal components were designed, fabricated, and assembled. In addition, several components were produced using 3D printing following mechanical analysis to validate structural integrity and functional performance.
Key Challenges
The primary challenge involved optimizing the profile and geometry of the holding mechanism to ensure stable and consistent performance under rotational conditions. A secondary challenge was creating sufficient space for the moving mechanism within the existing machine layout. This required innovative redesign and modification of selected machine components while maintaining overall machine performance, efficiency, and operational reliability.
Project Outcome
The final mechanism successfully met all functional requirements and performed reliably during testing and operation. The client expressed strong satisfaction with the solution and subsequently requested deployment of the same mechanism across additional machines.
