Compact Collator With Cross-Pusher Assembly
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Solution Overview
Problem
Conventional product collating and sorting systems are inflexible and require multiple changeovers and reconfigurations to handle containers of different sizes and shapes, resulting in increased time and cost, and have a large footprint.
Innovation Solution
A compact collator system that uses a cross-pusher assembly to collate and arrange product containers into any desired number or pattern, with a customizable cross-pusher arm that adapts to various container sizes and shapes, allowing for efficient conversion and reduced system footprint.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional collating systems use multiple diverters and collators to handle different container sizes and shapes, then the system can accommodate various packaging configurations, but the system footprint becomes large
Solution Approach 1:
The patent applies universality by designing a single collator assembly that can handle multiple container sizes and shapes through adjustable components. The collator assembly includes adjustable dividers and positioning mechanisms that can be reconfigured to accommodate different container dimensions, eliminating the need for multiple specialized collators and reducing the overall system footprint while maintaining versatility.
2Adaptability or versatility
If conventional systems replace diverters with different sizes to assemble containers of different sizes, then the system can create various container configurations, but multiple changeover parts are needed increasing time and cost
Solution Approach 1:
The patent applies dynamics by incorporating adjustable and reconfigurable components in the collator assembly that can be dynamically modified to handle different container sizes and configurations. The dividers, positioning mechanisms, and guide structures can be adjusted during operation or between runs to accommodate various container types, eliminating the need for complete part replacements and reducing changeover time while maintaining the ability to create diverse container configurations.
3Adaptability or versatility
If conventional collating systems use multiple laners, diverters and collators to assemble product containers into desired patterns, then various packaging arrangements can be achieved, but the system becomes complex
Solution Approach 1:
The patent applies merging by combining multiple functions into a single integrated collator assembly. The assembly integrates dividers, positioning mechanisms, guide structures, and transfer mechanisms into one unified device that can handle container collation, positioning, and pattern formation functions that would traditionally require separate components. This integration reduces the overall number of parts and simplifies the system while maintaining the ability to assemble containers into various desired patterns.
Data Source
AI summary
A compact collator for sorting and collating product containers includes a laner, a pattern conveyor, a cross-pusher assembly and a plurality of interchangeable inserts. The laner has a first movable conveyor for conveying product containers through the laner, and defines an infeed area. The pattern conveyor has a second movable conveyor positioned down-stream from the infeed area and off-set 90 degrees from the first moveable conveyor. The cross-pusher assembly includes a cross-pusher arm that the interchangeable inserts are configured to be engaged to. Each insert defines a unique face contour that corresponds to the profile shape of at least one type of product container.