Can Liner Re-Stacker Assembly for High-Speed Closure Stacking
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Solution Overview
Problem
Traditional liner machines are limited in operating speed and throughput due to inefficient re-stacking of container closures, which can result in shell damage, compound displacement, and suboptimal configurations like shingling, leading to jamming and reduced production output.
Innovation Solution
A re-stacker assembly with a motion control system and presence sensors to detect and control the motion of container closures, using a loading device like a kicker wheel to stack them in a predetermined manner, minimizing physical forces and ensuring proper orientation and spacing, aided by a vacuum to facilitate efficient re-stacking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional re-stacking methods are used, then the structure is simple, but the operating speed is limited to 2100 EPM or less
Solution Approach 1:
The patent replaces traditional mechanical re-stacking mechanisms with a motion control system that uses sensors and automated actuation. The presence sensor detects shell position and the motion control system coordinates the loading device accordingly, eliminating the need for complex mechanical timing mechanisms and enabling speeds exceeding 2100 EPM.
Solution Approach 2:
The patent implements feedback control by using a presence sensor to detect the position of container closures and feeding this information back to the motion control system. This feedback loop allows the system to dynamically adjust the loading device positioning and actuation timing, enabling high-speed operation without mechanical complexity.
2Productivity
If high-speed re-stacking is attempted without time-gating devices, then productivity increases, but shell damage and compound displacement occur
Solution Approach 1:
The presence sensor provides real-time feedback on shell position and motion state to the motion control system. This feedback enables the system to timing the loading device actuation precisely when needed, preventing shell damage and compound displacement while maintaining high-speed operation.
Solution Approach 2:
The system dynamically adjusts the loading device positioning and actuation timing based on real-time detection of shell motion. This dynamic control allows the system to adapt to variations in shell speed and position, preventing harmful forces from damaging shells or displacing compound during high-speed re-stacking.
3Productivity
If shells are re-stacked without motion control, then the device is simpler, but suboptimal configurations like shingling occur causing jamming
Solution Approach 1:
The presence sensor detects shell position and motion, providing feedback to the motion control system that coordinates the loading device to place shells in optimal configurations. This feedback mechanism prevents shingling and other suboptimal stacking patterns that cause jamming, while maintaining high re-stacking efficiency.
Solution Approach 2:
The patent replaces mechanical stacking mechanisms with a motion-controlled system that uses sensor feedback to coordinate shell placement. This substitution enables precise control over stacking configuration, eliminating shingling and jamming issues while maintaining high productivity.
4Speed
If compound is applied without proper time-gating during re-stacking, then processing speed increases, but compound spillover occurs
Solution Approach 1:
The presence sensor provides timing feedback that coordinates compound application with shell positioning. This feedback mechanism ensures compound is applied at the correct moment during re-stacking, preventing spillover while maintaining high processing speeds.
Solution Approach 2:
The system dynamically synchronizes compound application timing with shell motion and positioning detected by the presence sensor. This dynamic coordination prevents compound spillover during high-speed re-stacking operations by adjusting application timing to match shell movement.
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 processing speeds of up to 3500 ends per minute with reduced shell damage and compound displacement, allowing for efficient and high-speed re-stacking of container closures without jamming.
Implementation Method 1
a motion control system structured to detect motion of the container closures and in response to detecting such motion, drive the loading device to stack the container closures
Implementation Method 2
aided by a vacuum to facilitate efficient re-stacking
Data Source
AI summary
A re-stacker assembly used to stack container closures that are output by a can liner system includes at least one offloading assembly having a receiving portion, at least one loading device coupled to the offloading assembly, and a motion control system for detecting motion of the container closures and, in response to detecting such motion, driving the loading device to stack, or re-stack, the container closures in a predetermined manner.