Blanks Separation Using Oscillating Teeth and Air Beam
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Solution Overview
Problem
Current methods for separating magnetic and non-magnetic sheet or disc-shaped blanks, such as form-cut blanks, are inefficient and costly, particularly when dealing with non-magnetic materials like aluminum and plastic, as they often require manual intervention and are not adaptable to larger pallets or complex blank geometries, leading to material waste and quality issues.
Innovation Solution
A device using a separating unit with a moving means and teeth or spines to grip and lift blanks, accompanied by an air beam to eliminate vacuum, allowing for piece-by-piece separation of magnetic and non-magnetic blanks, including form-cut shapes, without the need for extensive space or modifications to existing equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If fanner magnets or compressed air are used to separate blanks, then separation speed is improved, but the method cannot handle non-magnetic materials or form-cut blanks effectively
Solution Approach 1:
The separating unit is divided into multiple fingers with teeth or spines that can independently engage with blanks of different geometries. This segmentation allows the device to adapt to various blank shapes including form-cut blanks, while maintaining automated separation capability.
Solution Approach 2:
The separating unit combines mechanical gripping elements (teeth or spines on fingers) with air beam capability in a single device. This multi-functional design enables the device to handle both magnetic and non-magnetic materials, as well as various blank geometries, replacing the need for separate systems.
2Force
If wide screw formed arrangements are used to separate blanks, then separation force is improved, but the device requires large space and cannot be used on larger pallets
Solution Approach 1:
The separating unit transitions from a lateral screw-driven mechanism to a vertical oscillating motion. The fingers move upward to engage blanks, then oscillate to separate them, utilizing the vertical dimension rather than requiring extensive lateral space. This allows operation over larger pallets without increasing footprint.
Solution Approach 2:
Instead of using screws to push blanks laterally, the invention uses vertically oscillating fingers that grasp and lift blanks upward. This inverted approach to force application achieves separation without requiring the large horizontal space and sub-level clearance needed by screw arrangements.
3Extent of automation
If suction pillows are used to transport blanks, then automated handling is improved, but the separation process cannot ensure piece-by-piece separation
Solution Approach 1:
Each finger of the separating unit has teeth or spines positioned to engage specific locations on the blank edge. This localized engagement ensures that only one blank is grasped at a time, providing precise control over piece-by-piece separation while maintaining automated operation. The air beam is also locally applied between specific blanks to assist separation.
4Productivity
If thread grooves are used to grasp blanks, then separation capability is improved, but chips are created on blanks causing quality problems
Solution Approach 1:
The teeth or spines on the fingers are designed to engage blanks without creating permanent damage. Unlike thread grooves that require blanks to slip and create chips, these elements provide controlled grasping that maintains blank quality, eliminating the need for expensive rework or scrap.
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 efficient, cost-effective, and automated separation of blanks, preventing material loss and quality issues, while being compact and adaptable to various blank geometries and larger pallets, ensuring continuous operation with reduced maintenance costs.
Implementation Method 1
the movement means is also feeding in an air beam between the actual blanks in order to eliminate vacuum between the same, which speeding up the separation by giving the uppermost blank a lifting force of that air cushion
Data Source
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AI summary
The invention relates to a method and a device to separate blanks (3) form each other in a stack (2) by that at least one separating unit (1) is brought into contact with one or more of the edges of the blank stack (2). The separating unit (1) comprises a separating arm (10) having a narrow teeth provided blade (13), which moves first horizontally until a tooth grasps the uppermost blank, whereupon the arm (10) having the narrow teeth provided blade (13) controllably moves upwards and lifts one blank edge. An air knife (15), which acts towards the side of the blank stack in a direct connection to the point of application of the teeth provided blade (13), can give one or several air thrusts when the blade (13) is starting its controlled movement upwards and is urging like an wedge in under a slit under the uppermost blank of the blank stack (2), an eventual existing vacuum between the blanks being disappeared at the same time as the uppermost blank of the blank stack (1) receives a lifting force by the air cushion, created.