Carton Stack Feeding with Foldable Teeth for Continuous Merging
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Solution Overview
Problem
Existing feeding devices for flat-folded carton stacks are inflexible and struggle to accommodate cartons of varying sizes and lengths efficiently.
Innovation Solution
A conveyor system with adjustable teeth that can be positioned in either an erected or folded state, allowing for flexible adaptation to different stack lengths, and a method to merge stacks at the outfeed region without disturbing the orientation of the cartons.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the distance between holding teeth is changed to accommodate different stack lengths, then the device can handle various carton sizes, but the device complexity increases due to multiple adjustment mechanisms
Solution Approach 1:
The conveyor system employs dynamically adjustable holding teeth that can change their spacing configuration during operation. The teeth are positioned on adjustable carriers that can be moved along the conveyor track, allowing the system to adapt its geometry to different stack lengths without requiring multiple fixed conveyor units.
Solution Approach 2:
The conveyor track is divided into multiple independent segments or zones, each with its own set of holding teeth on adjustable carriers. This segmentation allows different portions of the conveyor to be configured independently, enabling flexible adaptation to various stack lengths while keeping the overall system manageable in complexity.
2Length of stationary object
If teeth are removed or conveyor belts are replaced to increase distance between holding teeth, then greater distances can be covered, but the ease of operation and flexibility are reduced
Solution Approach 1:
Instead of static tooth configurations requiring physical removal or replacement, the system uses dynamically positionable teeth on adjustable carriers. These carriers can be moved along the track and locked into position, providing continuous adjustability without downtime or complex reconfiguration procedures.
Solution Approach 2:
The adjustable carriers serve multiple functions: they hold the holding teeth, provide positioning along the track, enable distance adjustment, and facilitate easy reconfiguration. This multi-functionality eliminates the need for separate adjustment mechanisms and simplifies operation.
3Productivity
If conventional feeding devices are used for regular rectangular cartons, then large stacks can be handled efficiently, but they cannot accommodate five-panel cartons with varying thickness
Solution Approach 1:
The holding teeth are mounted on adjustable carriers that can dynamically adapt their position and orientation. This allows the system to accommodate the varying thickness profiles of five-panel cartons while maintaining the productivity benefits of handling large stacks, as the carriers can be positioned to match the specific geometry of each carton type.
Solution Approach 2:
The adjustable carriers allow local adaptation of the holding teeth position to match the specific thickness distribution of different carton types. Each carrier can be independently positioned to accommodate the local geometry requirements, whether for uniform rectangular cartons or varying thickness five-panel cartons.
Data Source
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AI summary
A feeding device (1 ) for feeding stacks of standing flat-folded cartons (2) to a receiving station, comprising a conveyor track (30) having a flat bearing plane (3) adapted to support the stacks, where the conveyor track (30) comprises at least two rows of teeth (5, 6, 7) where each row of teeth (5, 6, 7) comprises a plurality of spaced apart teeth (17) adapted to support the stacks of flat-folded cartons (2), where the teeth (17) can be positioned in either an erected position or in a folded position, and where the feeding device (1) comprises a guide track (24) arranged along the bearing plane (3) adapted to hold the teeth (17) in the selected position, and where the guide track (24) ends at an end region (15) of the conveyor track (30), such that the teeth (17) are unsupported at the end region (15). The advantage of the invention is that stacks of flat-folded cartons can be merged continuously at an outfeed region.