Adjustable Star Wheel with Cam-Actuated Jaws
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Solution Overview
Problem
Conventional star wheels are not adjustable enough to accommodate containers of different sizes and shapes efficiently, requiring multiple star wheels and compromising on container support, which leads to inefficiencies in handling lines.
Innovation Solution
An adjustable star wheel design featuring interchangeable pockets with moveable jaws and a cam mechanism, allowing the star wheel to switch between larger and smaller pocket configurations, enabling precise tailoring of pocket shapes and sizes to match specific containers, providing multiple points of contact for secure support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a star wheel is designed with fixed pockets for specific container sizes, then container support precision is improved, but adaptability to different container sizes deteriorates
Solution Approach 1:
The star wheel incorporates moveable jaws that can change position between extended and retracted states, allowing the pocket configuration to dynamically adapt to different container sizes. This dynamic adjustment mechanism enables the same star wheel to precisely support both larger and smaller containers by modifying the pocket geometry on-demand.
Solution Approach 2:
The invention changes the physical parameters of the pockets by moving jaws between extended and retracted positions. When jaws are retracted, larger pockets accommodate bigger containers; when extended, smaller pockets are formed for smaller containers. This parameter change allows a single star wheel to maintain high support precision across multiple container sizes.
2Adaptability or versatility
If multiple star wheels are used to handle different container sizes, then adaptability is improved, but device complexity and space requirements worsen
Solution Approach 1:
The star wheel is designed with multi-functionality through its adjustable pocket configuration. A single star wheel can handle multiple container sizes by adjusting the jaw positions, eliminating the need for multiple dedicated star wheels. This universal design reduces device complexity while maintaining full adaptability to different container specifications.
Solution Approach 2:
The dynamic adjustment capability allows one star wheel to replace multiple static star wheels. By enabling the pocket configuration to change based on container size, the system achieves the functionality of multiple specialized star wheels through a single adaptable unit, thereby reducing overall device complexity.
3Adaptability or versatility
If moveable jaws are added to create adjustable pockets, then adaptability is improved, but device complexity worsens
Solution Approach 1:
A cam mechanism serves as an intermediary that translates rotational motion into the radial movement of jaws. This intermediary mechanism provides a simple and reliable way to adjust jaw positions without requiring complex actuators or control systems for each jaw, thus limiting the increase in device complexity while achieving full adaptability.
Solution Approach 2:
The invention replaces complex individual jaw actuation mechanisms with a unified cam-based system. Instead of using motors or hydraulic actuators on each jaw, a single cam mechanism coordinated with the star wheel rotation provides the necessary jaw movement, substituting a potentially complex mechanical control system with a simpler cam-follower arrangement.
4Manufacturing precision
If fixed star wheels are used for each container size, then container support precision is improved, but loss of time for changing star wheels worsens
Solution Approach 1:
The dynamic jaw adjustment mechanism allows the star wheel to be quickly reconfigured for different container sizes without physical replacement. Operators can simply adjust the jaw positions using the cam mechanism, achieving the same precision support as fixed star wheels but in a fraction of the time required to swap entire star wheel components.
Solution Approach 2:
The star wheel is pre-designed with the capability to accommodate multiple container sizes through its adjustable jaw mechanism. This preliminary design consideration eliminates the need for time-consuming star wheel changes, as the system is already configured to adapt to different container specifications through simple jaw position adjustments rather than component replacement.
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
Enables quick and efficient conversion between handling larger and smaller containers without the need for spare parts, ensuring accurate orientation and reduced movement of containers, improving handling line efficiency.
Implementation Method 1
a cam mechanism linking the jaws to the actuator disc such that rotation of the actuator disc causes substantially radial movement of the jaws between an extended position and a retracted position
Data Source
AI summary
The present invention provides an adjustable star wheel provided with at least one interchangeable pocket for receiving a container to be conveyed. The star wheel comprises a larger pocket of fixed shape and size, moveable jaws defining a smaller pocket having a fixed shape and size, an actuator disc rotatable about the central axis, and a cam mechanism linking the jaws to the actuator disc to cause radial movement of the jaws. In an extended position, the jaws move the smaller pocket into coincidence with the larger pocket thereby configuring the star wheel to receive containers in the smaller pocket. In the retracted position, the jaws are clear of the larger pocket thereby configuring the star wheel to receive containers in the larger pocket.