Cartoning Machine Pusher Mechanism for Intermediate Production Rates
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Solution Overview
Problem
Current cartoning machines are inefficient at production rates between 100-180 cycles/minute, as intermittent machines are underutilized and continuous machines are too bulky and costly for such rates, leading to unsatisfactory performance and increased space occupation.
Innovation Solution
A packaging apparatus with intermittent operation logic using a pair of pushers moving along predefined paths with a common active and return portion, allowing high productivity and structural simplicity, capable of operating effectively at 100-200 cycles/minute with modest dimensions and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If intermittent motion mechanisms are used, then space occupation and costs are reduced, but productivity is limited to approximately 120 cycles/minute
Solution Approach 1:
The single pusher is segmented into a first pusher and a second pusher that operate alternately. Each pusher handles a portion of the packaging cycle, allowing the system to maintain higher productivity through parallel operations while keeping individual component complexity manageable.
Solution Approach 2:
The pushers operate in periodic alternating fashion, with each pusher active during specific phases of the cycle and inactive during others. This periodic action allows the system to achieve higher average productivity while individual components experience reduced stress and simpler design requirements.
2Productivity
If continuous motion mechanisms are used, then productivity reaches 500-700 cycles/minute, but space occupation and costs increase significantly
Solution Approach 1:
By dividing the continuous pusher function into two separate pushers that operate alternately, the system achieves productivity closer to continuous machines (150-200 cycles/minute) while maintaining the compact footprint of intermittent machines. The segmentation allows overlapping operations that increase throughput without proportionally increasing space requirements.
Solution Approach 2:
The pushers transition between active and inactive states dynamically, with each pusher being movable during its active phase and stationary during its inactive phase. This dynamic operation allows the system to achieve higher productivity than traditional intermittent machines while avoiding the continuous space requirements of continuous motion machines.
3Productivity
If continuous motion mechanisms are used, then high productivity is achieved, but stress on mechanical components and products increases
Solution Approach 1:
Each pusher operates periodically rather than continuously, being active only during specific phases of the cycle. This periodic action reduces cumulative stress on each pusher and its associated components compared to continuous operation, while the alternating sequence maintains high overall productivity. The rest periods between active phases allow stress dissipation and reduce wear.
4Productivity
If continuous motion mechanisms are used, then high productivity is achieved, but device complexity and costs increase
Solution Approach 1:
The complex continuous motion system is segmented into two simpler intermittent pushers with distinct active and inactive phases. Each pusher has a simpler mechanical design compared to continuous motion mechanisms, but their coordinated alternating operation achieves productivity comparable to continuous systems. This segmentation reduces overall device complexity while maintaining high throughput.
Data Source
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AI summary
A packaging apparatus (1), of the type of cartoning machines and the like, comprising a first supply line (2) for supply of products (A) to be packaged, preferably of the type of pouches, blister packs, bottles, vials and the like, and a second supply line (3) for supply of containers (B) shaped substantially like a parallelepiped. The first line (2) and the second line (3) are movable according to an intermittent rule of motion and lead to a loading area (4), which is affected by a main insertion assembly (5), designed for the transfer of each product (A) into a respective container (B), for its packaging. The main assembly (5) comprises a drive unit for at least one main rotating shaft (6), at least one pair of pushers (7) being functionally associated with the main shaft (6) and acting along respective predefined paths, which comprise a common active portion and a return portion, which is different from the active portion, to allow the return of each pusher (7) to the initial position of the active portion. The active portion, which is followed in different respective active steps during an idle step of each line (2, 3), intersects the first supply line (2) and leads to the second supply line (3), to ensure the movement of the products (A) and their insertion in the containers (B).