Air Conveyor Bottle Orientation via Zoned Airflow
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Solution Overview
Problem
Air conveyor systems face difficulties in transferring plastic bottles to other transport devices due to the oblique position of bottles, which can cause issues during the transition from high-speed transport to other conveyor systems like sawtooth or zigzag stars.
Innovation Solution
The air conveyor system addresses this by applying air to the bottle bodies in the end area to orient bottles vertically, using guide plates with gills or nozzles and optional detectors to adjust airflow based on bottle position, ensuring minimal deviation from vertical orientation, thereby facilitating smooth transfer without slowing down the transport process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If air is applied only to bottle openings for high-speed transport, then transport capacity increases to over 30,000 bottles per hour, but bottles assume an oblique position that causes transfer difficulties to other conveyor systems
Solution Approach 1:
The air application process is segmented into two distinct zones: a first air application zone that applies air to bottle openings for propulsion, and a second air application zone that applies air to bottle bodies for vertical orientation. This segmentation allows each zone to perform its specific function optimally without interfering with the other, resolving the contradiction between maintaining high transport capacity and ensuring reliable transfer.
Solution Approach 2:
The second air application zone performs preliminary orientation of bottles to a vertical position before the bottles reach the transfer point. This preliminary action ensures that bottles are properly oriented for transfer to other conveyor systems, preventing transfer difficulties while maintaining the high-speed transport achieved in the first zone.
2Reliability
If air is applied to bottle bodies to orient them vertically, then transfer reliability improves, but transport speed may decrease
Solution Approach 1:
Air is applied to different parts of the bottles with different qualities: in the first zone, air is applied to bottle openings for propulsion; in the second zone, air is applied to bottle bodies for orientation. This local differentiation allows vertical orientation to be achieved without significantly impacting the forward momentum and transport speed of the bottles.
Solution Approach 2:
The air application occurs in periodic zones along the conveyor path, with the first air application zone providing propulsion and the second air application zone providing orientation. This periodic, zoned approach ensures that orientation occurs during transport rather than requiring a separate deceleration phase, maintaining overall transport speed while achieving reliable transfer orientation.
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
This approach enables precise vertical orientation of bottles with deviations less than 10°, increasing transport capacity from 30,000 to 120,000 bottles per hour and ensuring reliable transfer to other conveyor systems without interruptions.
Implementation Method 1
as speed is increasing, aerodynamic drag also plays an increasing role. As aerodynamic drag is highest in the area of the largest surfaces of action of the bottles
Implementation Method 2
When air is being applied to the bottle bodies, the air is preferably blown against the bottle bodies from the side or diagonally from the side
Data Source
AI summary
An air conveyor for transporting plastic bottles, in which bottles are driven by applying air, in the area of the bottle openings. In a partial area of the air conveyor, means are provided to apply air to the bottle bodies. These means are arranged such that the bottles are essentially oriented vertically with the openings of the bottles facing upwards and the bottom of the bottles facing downwards.