Gap-Free Bottle Row Formation Using Acceleration Conveyor
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Solution Overview
Problem
Existing transport apparatuses for transforming multiple-row streams of bottles into single rows often result in gaps, disrupting downstream treatment machines, especially when processing multiple rows, due to the need for multiple pressureless funnels and complex structural arrangements.
Innovation Solution
A transport apparatus with a multiple-lane feed conveyor, at least two single-lane discharge conveyors, and an acceleration conveyor with increasing speed sections, featuring diagonally oriented guides that guide sub-streams across the acceleration conveyor, allowing for continuous merging into railings and independent motor control to ensure gap-free single rows.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single pressureless funnel with a single diagonal guide means is used to transform a multiple-row stream into a single row, then the structural complexity is reduced, but gaps occur in the resulting single rows particularly in the row furthest from the guide means
Solution Approach 1:
The single diagonal guide means is divided into multiple separate diagonal guide means (at least two), each responsible for guiding a specific sub-stream of bottles. This segmentation allows each guide to independently control its respective sub-stream, preventing gaps in all rows including those furthest from the guides, while maintaining reasonable structural complexity through the shared acceleration conveyor
Solution Approach 2:
Multiple diagonal guide means are arranged at lateral distances from one another across the acceleration conveyor, creating a multi-dimensional guiding system. This spatial arrangement ensures comprehensive coverage of all bottle sub-streams simultaneously, eliminating gaps in all rows without requiring separate acceleration conveyors for each row
2Reliability
If separate pressureless funnels are provided for each individual row to achieve gap-free single rows, then the reliability of row formation is improved, but the structural complexity becomes considerable
Solution Approach 1:
Multiple diagonal guide means are merged onto a single shared acceleration conveyor structure. The guides operate independently to control their respective sub-streams, yet they share the common acceleration conveyor and control system, achieving gap-free formation in all rows while avoiding the complexity of multiple separate pressureless funnels
Solution Approach 2:
The single acceleration conveyor serves multiple functions by accommodating multiple diagonal guide means that simultaneously guide multiple sub-streams into separate single rows. This multi-functional design eliminates the need for separate acceleration conveyors for each row, reducing structural complexity while maintaining reliable gap-free row formation
3Device complexity
If a conventional pressureless funnel with a single diagonal guide means is used to produce a double row, then the structural complexity is reduced, but gaps occur in the two proceeding single rows particularly in the row furthest from the guide means leading to disruptions
Solution Approach 1:
The single diagonal guide means is segmented into multiple guides that independently control multiple sub-streams. This ensures continuous, gap-free delivery to all downstream positions, preventing disruptions to the treatment machine while maintaining a unified acceleration conveyor structure for continuous operation
Solution Approach 2:
The system incorporates monitoring devices on discharge conveyors that detect gaps and provide feedback to control devices. These control devices adjust the speeds of feed conveyor sub-sections and acceleration conveyor sections in real-time to prevent gap formation, ensuring continuous operation of downstream treatment machines
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The apparatus achieves gap-free formation of single rows using a single acceleration conveyor, ensuring continuous and efficient loading of packaging machines by controlling transport speeds and guide alignment, reducing structural complexity and disruptions.
Implementation Method 1
an acceleration conveyor arranged between the feed conveyor and the discharge conveyors, which acceleration conveyor comprises a plurality of sections having a speed which increases in the transport direction
Implementation Method 2
a guide which runs diagonally across the intermediate conveyor, wherein at least one second guide which runs diagonally across the acceleration conveyor is arranged at a lateral distance from the first guide, and in that the guides in each case guide a sub-stream of the stream of bottles or the like coming from the feed conveyor across the sections of the common acceleration conveyor
Data Source
AI summary
A transport apparatus for the low-pressure transforming of a stream of containers into at least two separate single rows is provided. The apparatus has a multiple-lane feed conveyor, a plurality of single-lane discharge conveyors and an acceleration conveyor arranged between the feed conveyor and the discharge conveyors. A plurality of diagonally oriented guides are provided at a distance from one another across the acceleration conveyor, which guides a separated sub-stream of the stream of containers coming from the feed conveyor across the sections of the acceleration conveyor.