Humanized Design Elements of The Transparent Film Three-dimensional Packaging Machine

The humanized design of the transparent film 3D packaging machine should take the needs of the operators as the core, and focus on safety, efficiency, comfort and ease of use. By optimizing the equipment structure and interaction mode, the labor intensity can be reduced and the operation experience can be improved. The following is an analysis from the perspectives of technical principles and practical applications:

First, the design of operational convenience

Optimization of touchscreen interaction

Interface hierarchical design: A three-level menu structure is adopted. Core functions (such as start/stop, parameter setting) are located on the home page, while secondary functions (such as fault record, maintenance log) are accessed through the secondary menu, reducing operation steps. For example, when switching packaging specifications, the operator only needs to click the "Specification Selection" button on the home page and directly select the model from the drop-down list, without having to delve into multi-level menus.

Dynamic prompt function: The touch screen integrates a dual prompt system of voice and vision. When the operator inputs incorrect parameters (such as the heat sealing temperature exceeding the tolerance range of the membrane material), a red warning box will pop up on the screen accompanied by a beeping sound, and at the same time display correction suggestions (such as "The current temperature is too high. It is recommended to reduce it to 160℃") to reduce the risk of misoperation.

One-click function integration

Quick mold changing system: It realizes the interlocking switching of heat sealing molds, cutting blades and conveying parameters through preset programs. For example, when switching from Specification A to Specification B, the operator only needs to press the "Specification B" button. The equipment automatically adjusts the heat sealing time (extending from 0.8 seconds to 1.2 seconds), the cutting position (lateral offset of 15mm), and ejects the corresponding mold. The mold changing time is shortened from the traditional 15 minutes to 3 minutes.

Self-reset function for faults: When the equipment detects minor faults (such as membrane material jamming), it automatically pauses and attempts self-correction three times (such as reverse rotation of the conveyor belt for 0.5 seconds). If the correction is successful, it resumes operation, reducing the need for manual intervention.

Second, safety protection design

Multi-level security interlocking mechanism

Grating protection system: Infrared gratings are installed on both sides of the feed port and the discharge port, with a beam spacing of no more than 50mm, forming a safety protection net with a width of 1.2 meters and a height of 0.8 meters. When a human body or foreign object enters the grating area, the equipment stops within 0.1 seconds to avoid the risk of pinching injury.

Two-handed start button: The control panel is equipped with two start buttons, with a spacing of ≥600mm. The operator needs to press both hands simultaneously to start the equipment to prevent the body from approaching dangerous areas due to one-handed operation.

Visual safety warning

Dynamic hazard area identification: The equipment casing uses LED light strips to outline the hazard areas (such as heat sealing modules and cutting units). During operation, the light strips flash red and turn green when at rest, providing a direct indication to the operator of the safe range.

Sound and light alarm classification: Three levels of alarms are set according to the severity of the fault (yellow warning, orange alarm, and red emergency stop). For instance, when the membrane material is exhausted, a yellow warning is triggered (beeping once per second); when the heat sealing temperature is abnormal, an orange alarm is triggered (beeping twice per second + red screen flashing); and when the transmission system gets stuck, a red emergency stop is triggered (continuous beeping + power failure of the equipment).

Third, ergonomic design

The height and Angle of the operation console are adjustable

Electric lifting control: The height of the operation console can be adjusted steplessly within the range of 700-900mm, suitable for operators of different heights. For instance, an operator who is 1.6 meters tall can adjust the tabletop to 750mm, while one who is 1.8 meters tall can adjust it to 850mm. Keep the elbows naturally hanging down to reduce shoulder and neck fatigue.

Tilt Angle adjustment: The touch screen supports a tilt Angle adjustment range of 0° to 30°. The operator can fine-tune the screen according to the line of sight Angle, avoiding cervical pressure caused by prolonged lowering or raising of the head.

Design for reducing burdens

Lightweight maintenance tools: Equipped with a retractable magnetic screwdriver and universal joint wrench, operators do not need to frequently change tools or overextend their arms when inspecting the interior of the equipment. For example, when changing the heat-sealing mold, the magnetic screwdriver can be attached to the metal part to prevent the tool from falling and injuring people.

Facilitating the handling structure: The equipment shell is equipped with hidden handles and casters, allowing a single person to push the equipment (weight ≤300kg) for short-distance movement. The surface of the handle is made of anti-slip silicone material, which increases the holding force by 30% and reduces hand fatigue.

Fourth, maintain friendly design

Modular quick-disassembly structure

Tool-free disassembly of the heat-sealing module: With the design of snap fasteners and guide rails, the heat-sealing module can be disassembled and installed within 5 minutes. For example, when replacing the heat seal, the operator only needs to press the two side clips and slide the module outward, without tools such as screwdrivers.

Visual maintenance window: A transparent observation window is set on the side of the equipment, covering key parts such as the electrical cabinet and transmission system. The operator can check the cable connection status, lubricating oil level, etc. through the observation window without having to stop the machine and open the cover.

Intelligent maintenance guidance

Ar-assisted maintenance: By scanning the device's QR code, operators can use their mobile phones or AR glasses to obtain 3D maintenance guidance. For example, when changing the cutting blade, the AR interface will superimpose virtual arrows to indicate the position of the bolt and mark the torque parameters (such as "M6 bolt, torque 8N·m").

Maintenance plan push: The device automatically generates a maintenance plan based on the operating duration and load data, and pushes reminders through the touch screen. For example, after a cumulative operation of 1,000 hours, it prompts "It is recommended to replace the lubricating oil", along with the operation steps and a list of spare parts.

Fifth, environmental adaptability design

Noise reduction and vibration damping

Sound insulation cover and vibration damping base: Sound insulation covers are installed on the top and sides of the equipment, with polyester fiber sound-absorbing cotton filled inside to reduce noise to below 75dB (A). The base is equipped with rubber vibration damping pads to reduce the transmission of equipment vibration to the ground and avoid affecting adjacent workstations.

Local lighting optimization: Integrate LED strip lights in the operation area, with a color temperature of 4000K (neutral white light) and an illuminance of ≥500lx, ensuring that operators can clearly observe the equipment status even in low-light conditions.

Convenience of cleaning

No dead corner shell design: The equipment shell adopts a rounded corner transition and inclined surface flow diversion structure to prevent the accumulation of dust and debris. For instance, an inclined guide plate is set below the heat-sealing module, allowing the waste film to automatically slide down to the collection box without the need for manual cleaning.

Waterproof and dustproof structure: The control cabinet and motor have a protection level of IP54, with an anti-oil coating on the surface. Operators can directly wipe them with a damp cloth to reduce cleaning time.

Sixth, humanized design cases

Case of a certain enterprise: By introducing a two-hand start button and dynamic hazard area signs, the probability of operators accidentally coming into contact with the hazard area has decreased by 80%, and the rate of work-related injuries has dropped by 65%.

Practice in a certain workshop: After adopting the electric lifting operation platform, complaints about shoulder and neck fatigue from operators have decreased by 70%, and production efficiency has increased by 15% (as operators can stay focused for a longer time).

The humanized design of the transparent film three-dimensional packaging machine should be centered on the operator. Through comprehensive optimization of operational convenience, safety protection, ergonomics, maintainability and environmental adaptability, the equipment can achieve efficient, safe and comfortable operation. In the future, with the development of intelligent sensing and interaction technologies, devices will have stronger adaptive capabilities, further reducing labor intensity and enhancing user experience.