Circular Puck Orientation via Gear Rack Mechanism
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Solution Overview
Problem
Existing article handling systems face challenges in orienting and transporting asymmetric articles, particularly due to issues with puck shape and configuration, leading to random orientation, skewing, and jamming, which complicates operations like label printing and packaging.
Innovation Solution
A circular puck system with an upper annular plate and a lower annular puck plate featuring a recessed rack of gear-like teeth and a bridge, allowing for consistent angular orientation of articles through engagement with an elongated gear rack and linear star conveyor, enabling smooth and positive transport and accumulation of asymmetric articles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If rectangular pucks are used to hold asymmetric articles, then the articles can be held in one orientation, but the pucks skew, jam or generate orientation problems during conveying
Solution Approach 1:
The patent applies this principle by replacing the rectangular puck shape with a circular puck shape. The circular geometry eliminates the corner issues that cause skewing and jamming during conveying, while the recessed tooth assembly maintains the ability to hold asymmetric articles in the correct orientation. The curved perimeter allows smooth circulation through the system without the orientation problems associated with rectangular pucks.
2Manufacturing precision
If flat-sided rectangular pucks are used, then articles are held in one orientation, but re-orientation is complicated and accumulation requires very long apparatus
Solution Approach 1:
The circular puck design enables compact accumulation where multiple pucks can be stacked or arranged in a circular pattern, eliminating the need for very long linear accumulation apparatus. The circular geometry allows pucks to be accumulated in a space-efficient manner while maintaining the recessed tooth assembly that ensures proper article orientation.
Solution Approach 2:
The circular puck with recessed tooth assembly serves multiple functions: it holds asymmetric articles in the correct orientation, enables random accumulation of pucks, and facilitates easy re-orientation through the gear rack mechanism. This multi-functionality reduces the need for separate specialized apparatus for each operation.
3Speed
If rectangular pucks are conveyed, then transport is achieved, but the pucks skew and jam
Solution Approach 1:
The circular puck shape eliminates the corner-related skewing and jamming problems that occur with rectangular pucks during conveyance. The smooth circular perimeter allows the pucks to move freely through the system at high speeds without the orientation problems and mechanical interference that plague rectangular designs.
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
The system ensures repeatable, accurate, and efficient angular orientation of articles at high speeds, allowing for random accumulation and orientation, even after processes like filling, sealing, labeling, and inspection, without the need for special guiding features, ensuring consistent product handling.
Implementation Method 1
A recessed rack of a plurality of gear-like teeth, wherein the rack has two ends separated by a bridge of smooth, flat configuration from one end of the rack to the other, is disposed just within the periphery
Implementation Method 2
Puck transfer is by frictional bias from the underlying conveyor
Data Source
AI summary
An asymmetric article-carrying puck is driven by a linear star conveyor through an angular rotation orienting section to orient the pucks and articles therein irrespective of random initial orientation. In one embodiment, an upper puck plate carries the article while a separated lower puck plate defines a rotational orienting circular gear rack with a rotation-stopping bridge, separating ends of the rack and inclined from a base of one end tooth in the rack to a crest of another end tooth in the rack. The lower puck plate can be a combination of two circular plates with the circular gear rack interposed therebetween and within the periphery of the circular plates. Pucks can be accumulated in mutual engaged positions and separated by the linear star into preselected pitch while transported and turned. Integral pucks can be used. The structural details and methods are disclosed.