Adjustable Conveyor Belt Ejection for Cardboard Blanks
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Solution Overview
Problem
Existing ejection stations for carton blanks are inadequate at high speeds and with stiffer blanks, often failing to divert defective cartons in time, leading to them being unintentionally stacked with good ones due to sluggish flap mechanisms.
Innovation Solution
The ejection station features adjustable conveyor belts that can pivot as flap belts, allowing for independent adjustment and operation, enabling faster and more precise ejection of faulty cartons, even at high speeds, with additional mechanisms like higher-speed discharge belts and position detection sensors to optimize the ejection process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If a mechanical flap mechanism is used for ejecting defective carton blanks, then the ejection station works satisfactorily at relatively low process speeds, but it becomes too sluggish at higher transport speeds (5700 mm/s and more) to divert stiffer carton blanks in time
Solution Approach 1:
The patent applies dynamics by replacing the traditional mechanical flap mechanism with a movable conveyor belt system that can dynamically adjust its position and speed. The conveyor belt can be moved laterally to deflect carton blanks onto a side conveyor, and its speed can be independently controlled to match or exceed the main conveyor speed, enabling reliable ejection at high transport speeds of 5700 mm/s and more.
Solution Approach 2:
The patent changes the operational parameters by allowing the conveyor belt to operate at variable speeds and positions. The belt can be accelerated to match the high speed of the main conveyor while simultaneously being positioned laterally to intercept and divert defective carton blanks, thus maintaining ejection reliability across a wide range of transport speeds.
2Productivity
If the transport speed is increased to improve throughput and production efficiency, then productivity improves, but the time available for quality checking and ejection of faulty carton blanks is reduced
Solution Approach 1:
The patent ensures continuous useful action by having the conveyor belt system operate continuously at high speeds without interruption. The belt can continuously intercept and divert defective carton blanks while maintaining the high throughput speed of the main conveyor, eliminating any loss of time that would occur with slower ejection mechanisms.
Solution Approach 2:
The patent substitutes the traditional mechanical flap ejection system with a conveyor belt-based system that uses controlled lateral movement and speed variation instead of rapid mechanical opening and closing. This substitution enables the system to maintain high productivity while providing sufficient time for quality checking and ejection.
3Device complexity
If a flap mechanism is used to divert carton blanks, then the system is simple in structure, but it cannot handle stiffer carton blanks with wall thicknesses of a few centimeters at high speeds
Solution Approach 1:
The patent achieves universality by designing a conveyor belt system that can handle multiple types of carton blanks with different stiffness and thickness characteristics. The same conveyor belt mechanism can adapt to handle both flexible and stiff carton blanks by adjusting its speed and lateral movement, making the system versatile for different product types without requiring separate mechanisms.
Data Source
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AI summary
The invention relates to a reject station (10) for a manufacturing device for producing and/or processing cardboard blanks (1), as well as a manufacturing device and a method for rejecting cardboard blanks (1), wherein the reject station can automatically reject defective cardboard blanks (1) from a manufacturing process, comprising at least one upper conveyor belt (2) and one lower conveyor belt (3) between which the cardboard blanks are conveyed, at least one upper discharge conveyor belt (4) and one lower discharge conveyor belt (5) which are located behind the conveyor belts (2, 3) in the direction of a conveying section (6), means for detecting defective cardboard blanks (1), and a rejection section (7) which branches off obliquely from the conveying section (6), characterized in that at least one of the conveyor belts (2, 3) is provided with a deflection (8).by means of which it can be adjusted, at least section by section, from the direction of the conveying section (6) towards the discharge section (7) as a kind of flapping belt.