Multi-Lane Article Gripper Reorientation for Gap Filling
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Packaging systems face challenges in article handling due to asymmetrical article shapes, inconsistent orientation, and gaps in article infeed streams, leading to incomplete article groups and waste, with existing solutions either accepting waste or incurring additional costs for equipment and labor.
Innovation Solution
A two-stage transfer apparatus with gripper sets that lift and reorient articles, using an intermediate transfer station with rotatable trays and a bucket conveyor to form complete and oriented article groups, addressing asymmetry and gaps by expanding or collapsing gripper spaces and rotating articles for optimal packaging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If articles are fed in multiple closely spaced lanes, then floor space is reduced and equipment cost is lowered, but article re-orientation becomes difficult or impossible due to interference between adjacent articles
Solution Approach 1:
The transfer apparatus is divided into multiple independent transfer stations, each handling a specific lane. Each station has its own gripper mechanism that can independently re-orient articles without interfering with adjacent lanes, enabling re-orientation in closely spaced multi-lane configurations
Solution Approach 2:
An intermediate transfer station is introduced between the multi-lane infeed and the final packaging conveyor. This intermediary station provides the necessary space and mechanisms for article re-orientation, allowing articles to be picked up, re-oriented, and placed in the correct orientation for packaging
2Device complexity
If traditional transfer mechanisms are used, then equipment complexity is low, but gaps in article infeed streams cannot be filled resulting in incomplete article groups and waste
Solution Approach 1:
The system performs preliminary detection of article presence in each lane before transfer. When a gap is detected, the system prepares ahead by identifying articles from other lanes that can be re-oriented and positioned to fill the gap, preventing incomplete groups before they occur
Solution Approach 2:
The transfer apparatus dynamically adjusts its operation based on real-time detection of article gaps. The system can selectively activate different transfer stations and re-orientation mechanisms to fill gaps, adapting the transfer process to the actual article flow pattern rather than following a fixed sequence
3Adaptability or versatility
If articles are re-oriented in closely spaced lanes, then article orientation for packaging is improved, but article interference between lanes increases causing handling problems
Solution Approach 1:
The re-orientation function is segmented into separate transfer stations for each lane. Each station has dedicated grippers and rotation mechanisms that operate independently, eliminating interference between adjacent lanes while maintaining the ability to re-orient articles as needed
Solution Approach 2:
Article re-orientation is achieved by moving articles vertically to an intermediate elevation at the transfer station, performing rotation in this elevated position, and then placing them back on the conveyor. This dimensional change allows re-orientation without lateral interference with adjacent lanes
Data Source
AI summary
Article packaging apparatus includes a multiple lane article infeed, first and second transfers, an intermediate article orientation station and an article group discharge conveyor. The first and second transfers have respective article grippers expansible and contractible toward and away from one another while the intermediate article orientation station includes article rotating trays spaced further apart then the lanes of the article infeed.