Carousel Container Handling With Linear Motors for Fast Format Changes
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Solution Overview
Problem
Carousel machines for processing containers require significant downtime and are not versatile enough to handle multiple container formats efficiently, necessitating frequent disassembly and replacement of star conveyors.
Innovation Solution
A carousel machine with linear motor-driven handling carriages and adjustable jaws that allow for rapid format changes by reprogramming control means and minimal hardware adjustments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If star conveyors are disassembled and replaced for format changes, then the machine can process different container formats, but the machine downtime increases significantly
Solution Approach 1:
The patent applies the dynamics principle by replacing static, fixed star conveyors with a dynamic system where container support elements can be quickly repositioned and reconfigured. The linear motor-driven carriages enable rapid movement of container handling elements along the carousel, allowing the same physical structure to adapt to different container formats without disassembly, thus resolving the contradiction between format versatility and machine downtime
Solution Approach 2:
The patent segments the star conveyor function into modular components - specifically, the container support elements are separated from the fixed carousel structure and mounted on movable carriages. This segmentation allows individual elements to be independently repositioned for different formats while the main carousel structure remains intact, eliminating the need for complete disassembly and replacement during format changes
2Adaptability or versatility
If multiple container formats are processed in the same work cycle, then the machine versatility improves, but the device complexity increases
Solution Approach 1:
The patent implements universality by designing a single carousel machine structure that can handle multiple container formats through the programmable linear motor system. The same carriages and container support elements serve multiple functions by being repositioned to different locations on the carousel, eliminating the need for separate dedicated conveyors for each format and managing complexity through software control rather than hardware multiplication
3Speed
If linear motor-driven carriages are used for container handling, then the format change speed increases, but the manufacturing cost increases
Solution Approach 1:
The patent replaces traditional mechanical drive systems (gears, belts, motors mounted on each carriage) with a linear motor system that uses electromagnetic fields for direct linear motion. This substitution reduces the number of mechanical components needed, simplifies the drive mechanism, and enables precise, rapid positioning for format changes. While linear motors have higher unit cost, the overall system complexity and component count are reduced, and the rapid format change capability is achieved with fewer moving parts
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 quick format changes and versatile processing of diverse container formats with enhanced reliability, safety, and reduced downtime.
Implementation Method 1
The loading/unloading means 5 comprise at least one linear motor 6, which comprises a stationary track 7 with a closed extension, which constitutes the fixed part of the linear motor, and handling carriages 8a, 8b, 9a, 9b, 10a, 10b for conveying the containers 4, which are mounted so that they can move slidingly and in mutual succession along the track 7 and constitute in turn the translating part of the linear motor 6
Data Source
AI summary
A carousel machine for processing containers includes a rotating carousel, provided peripherally with pans for supporting the individual containers to be processed, and a device for loading/unloading the containers from the carousel. The loading/unloading device includes at least one linear motor which has a stationary track with a closed path and handling carriages, which are mounted so that they can move slidingly and in mutual succession along the track and each support at least one respective jaw adapted to cooperate with a jaw supported by a contiguous carriage in order to engage, on mutually opposite sides, a container to be transferred or picked up from the carousel. Control of the linear motor is provided and is adapted to actuate variation of the mutual distance of mutually contiguous carriages in order to allow the release or clamping of a container by the corresponding jaws.