Integrated Bar Conveyor for Flexible Tissue Stacking
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Solution Overview
Problem
Traditional flexible packaging lines for rolled sanitary tissue products are inefficient in handling both single-layer and multi-layer units, requiring significant reconfiguration efforts to switch between configurations, leading to reduced productivity and increased costs.
Innovation Solution
A flexible apparatus with an integral lifting device and independent flight bars that maintain both downstream and upstream control, allowing for efficient transfer and stacking of single-layer and multi-layer units without the need for extensive reconfiguration, by using independent flight bars to push units from behind while engaging the leading edge, ensuring continuous control during the process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional apparatus uses separate bar conveyor and lifting device, then stacking operation is enabled, but single-layer unit transfer efficiency is reduced and reconfiguration is required
Solution Approach 1:
The patent combines the bar conveyor and lifting device into a single integrated apparatus where the bar conveyor surface serves dual purposes: conveying single-layer units and providing the stacking surface for multi-layer units. This integration eliminates the need for separate devices and allows the system to efficiently handle both single-layer and multi-layer configurations without reconfiguration.
Solution Approach 2:
The bar conveyor is designed to perform multiple functions: it conveys single-layer units forward, provides a stacking surface for multi-layer units, and maintains control during both operations. This multi-functionality allows the apparatus to adapt to different packaging configurations (single-layer vs. multi-layer) without requiring separate dedicated mechanisms for each operation.
2Productivity
If traditional apparatus reconfigures from dual unit to single-layer configuration, then single-layer transfer efficiency improves, but equipment removal and repositioning are required
Solution Approach 1:
The integrated bar conveyor is designed to universally handle both single-layer and multi-layer units without requiring reconfiguration. The same apparatus and mechanism perform both functions, eliminating the need for equipment removal, repositioning, or complex reconfiguration efforts when switching between operational modes.
3Reliability
If traditional apparatus uses pusher to advance units from lifting plate, then control is maintained, but productivity is reduced
Solution Approach 1:
The patent merges the conveying function with the control function by using the bar conveyor surface itself to both move the units and maintain control during the transfer process. This eliminates the need for a separate pusher mechanism, allowing continuous high-speed operation while maintaining reliable control through the integrated design.
Data Source
AI summary
A method for transferring and/or stacking products, the method including providing a first plurality of products as a first unit, pushing the first unit onto a lifting plate, lowering the plate, providing a second plurality of products as a second unit, pushing the second unit onto the top of the first unit to create a stack.