Automated Adjustable Star Wheel for Conveying Articles
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Solution Overview
Problem
Existing star wheels on automated handling lines are limited in accommodating various sizes and shapes of articles, requiring frequent changes and maintaining multiple sizes, which is time-consuming and inefficient.
Innovation Solution
An adjustable star wheel with few moving parts, utilizing rotatable disks with control surfaces that form pockets of varying width and depth, adjusted by rotating the disks to accommodate different article shapes and sizes, and an automated adjustment mechanism, such as pinion gears or quick-change cams, to automatically adjust the star wheel configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional star wheels are used with fixed configurations, then the structure is simple and reliable, but the adaptability to different article sizes and shapes is limited
Solution Approach 1:
The star wheel employs dynamically adjustable pockets formed by pairs of contact surfaces on rotatable disks. These pockets can be repositioned radially and rotationally to accommodate varying article dimensions, transforming a static structure into a dynamic one that adapts to different conveying requirements without requiring multiple fixed star wheels
Solution Approach 2:
A single star wheel device performs multiple functions by adjusting its pocket configuration. The same physical structure can handle articles of different sizes and shapes by repositioning contact surfaces, eliminating the need for separate dedicated star wheels for each article type and reducing overall system complexity
2Productivity
If multiple star wheels of different sizes are maintained to handle various articles, then each star wheel can be optimized for its specific article type, but the loss of time for changing star wheels and the need to keep stock of different sizes increases
Solution Approach 1:
The star wheel dynamically reconfigures its pocket positions through automated adjustment mechanisms that rotate disks to different angular orientations and radially adjust contact surface positions. This allows the same physical star wheel to be quickly reconfigured for different article types without physical replacement, eliminating changeover time and maintaining continuous conveying operations
Solution Approach 2:
The adjustment mechanisms are pre-programmed with position data for different article types, allowing the star wheel to be automatically configured in advance before article type changes are required. This preliminary setup eliminates the need for manual intervention and physical star wheel replacement during operation
3Adaptability or versatility
If complex mechanical arrangements with piston elements and multiple rotating disks are used to provide adjustability, then the adaptability improves, but the device complexity and number of moving parts increases
Solution Approach 1:
The star wheel is segmented into multiple independent rotatable disks, each capable of being adjusted individually. This segmentation allows flexible combination of different disk configurations to create various pocket shapes and sizes, achieving high adaptability while keeping each individual disk simple in structure and reducing overall mechanical complexity compared to monolithic adjustment mechanisms
Data Source
AI summary
A universally adjustable star wheel for conveying articles on an automated handling line is disclosed. In one embodiment, the adjustable star wheel includes rotatable elements that are configured to rotate around a central axis. Each rotatable element has a central axis, a periphery, and at least one control surface for assisting in controlling the article being conveyed. The control surfaces on the rotatable elements are arranged to together form at least one pocket for the article, wherein the pocket has a width and a depth. The angle defining the control surface on at least one rotatable element is different from the angle of another rotatable element to form the depth of at least a portion of the pocket. In this embodiment, the boundaries of the pocket are configured solely by at least partially rotating at least some of the rotatable elements to adjust the location of the control surfaces of the different rotatable elements to form a pocket for the article being conveyed. An automated adjustment mechanism for adjusting a star wheel to accommodate different articles is also disclosed. The automated adjustment mechanism may be used with any suitable star wheel.