Container Carrier Cutoff Drum for High-Speed Multipack Application
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Solution Overview
Problem
Conventional container carrier application technology lags behind in handling high volumes efficiently, particularly for rigid, 100% curbside recyclable materials like HDPE and PET plastics, due to cumbersome manual processes or slow systems.
Innovation Solution
A system and apparatus utilizing a robotic applicator with an applicating drum, push down wheel, and cutoff system to efficiently apply container carriers made from 100% curbside recyclable plastics to groups of containers, forming multipacks at high speeds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual or slow application systems are used for rigid container carriers, then ease of operation is maintained, but productivity is significantly reduced
Solution Approach 1:
The patent replaces manual mechanical application with an automated robotic system featuring a programmable controller, robotic arm, and automated positioning mechanisms. This substitution enables high-speed application of rigid container carriers while eliminating the need for cumbersome hand application, directly resolving the contradiction between productivity and device complexity.
Solution Approach 2:
The system incorporates self-positioning features where the robotic arm automatically locates and aligns container carriers with containers through sensors and feedback mechanisms. The programmable controller autonomously manages the application process, reducing the need for complex manual intervention while maintaining high productivity.
2Loss of time
If traditional application methods are used, then device complexity is low, but loss of time occurs due to slow processing
Solution Approach 1:
The robotic system operates continuously with automated carrier feeding, positioning, and application cycles. The programmable controller coordinates continuous motion of the robotic arm and synchronized positioning mechanisms, eliminating idle time between applications. This continuous operation dramatically reduces total application time while the automation handles the increased system complexity.
Solution Approach 2:
The system pre-positions container carriers and pre-coordinates robotic arm movements before actual application occurs. Sensors detect container positions in advance, and the programmable controller pre-calculates optimal application paths, minimizing reactive adjustments and reducing overall application time despite complex system requirements.
3Productivity
If high-speed application systems are implemented, then productivity increases, but device complexity increases
Solution Approach 1:
The robotic system is designed with multi-functional capabilities, where a single robotic arm performs multiple operations including carrier pickup, positioning, and application. The programmable controller manages diverse functions through unified software, reducing the need for multiple specialized devices and thereby managing complexity while achieving high productivity.
Solution Approach 2:
The patent combines several functions into integrated components: the robotic arm integrates positioning and application functions, sensors combine detection and feedback roles, and the programmable controller unifies coordination of all subsystems. This merging reduces the number of separate components needed, managing device complexity while enabling high-speed operation.
Data Source
AI summary
A system, method and apparatus for applying container carriers to unitize a plurality of containers. A supply of container carriers are provided in connected sticks of two or more container carriers. An applicating drum is configured to accept a single container carrier stick from a queue and provide the container carrier stick to a supply of containers. A cutoff system is configured to cut the sticks of two or more container carriers into individual container carriers but not cut between adjacent unconnected sticks of container carriers.