Adjustable Layboy Conveyor for Scrap Reduction and Blank Alignment
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Solution Overview
Problem
Conventional stacker layboy sections face issues with excessive scrap material from die cut machines entering the transport path, causing alignment problems and jams, as the gap between the layboy and die cut machine is difficult to optimize due to varying blank sizes and scrap production.
Innovation Solution
An adjustable layboy conveyor with a movable upstream end of the lower conveyor section allows for dynamic adjustment of the gap between the layboy and die cut machine, balancing scrap reduction and blank alignment control by empirically determining and recording optimal gap sizes for specific blank sizes and shapes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the gap between the layboy and die cut machine is reduced to maintain blank alignment control, then blank orientation control is improved, but scrap material accumulation increases
Solution Approach 1:
The patent applies the dynamics principle by making the layboy conveyor adjustable in length, allowing it to dynamically adapt between two extended positions. This enables the system to optimize the gap distance between the layboy and die cut machine based on operational needs - extending the layboy to increase gap distance for scrap reduction, or retracting to decrease gap distance for improved blank alignment control.
2Reliability
If the layboy is positioned closer to the die cut machine to prevent blank sagging, then blank transport control is improved, but scrap material enters the transport path more easily
Solution Approach 1:
The adjustable length mechanism allows the layboy to dynamically reposition itself, enabling operators to extend the layboy when scrap reduction is prioritized or retract it when blank transport control is prioritized, thus resolving the contradiction between these two requirements.
3Object-affected harmful factors
If the gap distance is increased to reduce scrap accumulation, then scrap interference is reduced, but blank alignment control deteriorates
Solution Approach 1:
By making the layboy length adjustable, the system can dynamically optimize the gap distance - extending the layboy to increase gap distance for scrap reduction, or retracting to decrease gap distance for improved blank alignment control, thus resolving the contradiction between these opposing requirements.
Data Source
AI summary
A layboy conveyor includes a first end and a second end and an upper conveyor having a top and a bottom and a first end and a second end and a lower conveyor having a top and a bottom and a first end and a second end. The lower conveyor top is disposed adjacent to the upper conveyor bottom and defines with the upper conveyor bottom a transport path configured to transport a sheet of material in a direction from the first end of the layboy conveyor to the second end of the layboy conveyor. A drive is operably connected to the upper conveyor and to the lower conveyor, and the drive is configured to drive the upper conveyor bottom and the lower conveyor top in the direction. A length of the lower conveyor top is adjustable.