Cartoning Machine Comb-Shaped Pushers Staggered Rows
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Solution Overview
Problem
Conventional cartoning machines face limitations in operating speed and are costly due to reliance on manipulator robots, struggle with non-uniform package manipulation, and inefficient space utilization for products like Doypack™, leading to imperfections and high maintenance expenses.
Innovation Solution
A cartoning method and machine that uses comb-shaped pushers to position and compact packages in staggered rows, ensuring uniform translation and compact bundling, with movable walls for efficient space utilization and high-speed processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manipulator robots are used to create staggered rows of packages, then the packages can be positioned in intersecting rows to increase containment capacity, but the operating speed is greatly limited by the robot speed
Solution Approach 1:
The patent replaces manipulator robots with a mechanical system consisting of a conveyor belt and comb-shaped pushers. The pushers have teeth that engage with the packages to push them laterally by a predetermined distance, creating staggered rows mechanically rather than through robotic manipulation. This substitution eliminates the speed limitations of robots while maintaining positioning precision.
Solution Approach 2:
The comb-shaped pushers are segmented into multiple teeth that can selectively engage with individual packages or groups of packages. This segmentation allows the system to process multiple packages simultaneously through different pushing actions, increasing overall productivity while maintaining precise control over each package's final position in the staggered arrangement.
2Manufacturing precision
If manipulator robots are used for package manipulation, then staggered rows can be created, but investment and maintenance costs are very high
Solution Approach 1:
The patent employs simple, inexpensive mechanical components (conveyor belt, comb-shaped pushers made of basic materials) instead of expensive robotic systems. These components are designed for high durability and ease of replacement, providing a cost-effective solution that eliminates the high investment and maintenance costs associated with manipulator robots while achieving the same functional result.
3Device complexity
If packages are placed side by side in parallel rows, then the structure is simple, but empty spaces are created inside the packaging reducing containment capacity
Solution Approach 1:
The patent creates asymmetric staggered rows where alternating packages are offset laterally by a predetermined distance. This asymmetric arrangement allows packages with elliptical bases to interlock more efficiently, eliminating empty spaces between adjacent rows and maximizing the containment capacity of the packaging without requiring complex positioning mechanisms.
Data Source
AI summary
A cartoning machine and method, particularly for products organized in parallel and mutually staggered rows, the method comprising the following steps: - positioning, by way of a positioning device (4), a plurality of packages (3) in a gathering station (2) in such a manner that the packages (3) are standing and organized in a row with respect to each other on a working surface (5), - translating the packages (3) arranged on the working surface (5) from the gathering station (2) to a compaction station (6) by way of the actuation of two pushers (9) which are substantially comb-shaped so as to have two pluralities of teeth (10a, 10b) that are mutually alternated and can be arranged at the packages (3) with the two pushers (9) being mutually integral in translation, so as to produce a uniform translation of all of the packages (3), - moving part of the packages (3) inside the compaction station (6) by way of the translation of one of the pushers (9) with respect to the other, so as to create at least two rows of packages (3) which are alternately mutually offset, - retracting the pushers (9) into the gathering station (2) in their initial position, - compacting the packages (3) by way of the mutual approach of two movable walls (12), which delimit laterally the compaction station (6) in order to define a compact bundle (7) to be cartoned, - evacuating the compact bundle (7) from the compaction station (6) to a cartoning station (8).