Configuring Device for Tapered Article Nesting
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Solution Overview
Problem
Conventional cartoning machines face challenges in efficiently packaging tapered shape articles, such as coffee capsules, due to limitations in arranging articles in optimal formats, especially when dealing with odd numbers of rows, minimum transversal distance between rows, and complex multi-level arrangements, which restricts versatility and increases costs.
Innovation Solution
A configuring device with motorized and adjustable article-carrying seats allows for varying transversal distances between rows, enabling a second robot to compact articles into boxes efficiently, and supports independent work cycles for different robots, facilitating alternate flipping and nesting of articles within rows.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional top loading robots are used to load articles directly from inlet area to boxes, then the loading process is simple, but the ability to achieve nesting arrangement and optimize space utilization is limited
Solution Approach 1:
The patent introduces an intermediate station with support elements as a mediator between the inlet area and the loading area. This intermediate station enables articles to be transferred, repositioned, and compacted before final loading into boxes, thereby achieving nesting arrangements that would be difficult to accomplish with direct robot loading alone.
Solution Approach 2:
The intermediate station performs preliminary actions by receiving articles from the inlet area, positioning them on support elements, and compacting them into the desired nesting arrangement before the actual loading into boxes occurs. This preliminary organization enables complex space optimization without complicating the final loading operation.
2Quantity of substance
If articles are arranged in nested configuration to optimize space, then space utilization and transportation costs are reduced, but the complexity of forming such arrangements increases
Solution Approach 1:
The intermediate station with its movable support elements acts as a mediator that simplifies the formation of nested arrangements. The support elements can be positioned and moved to facilitate compacting articles into nested configurations, reducing the overall complexity of achieving space optimization.
Solution Approach 2:
The support elements of the intermediate station are made movable and adjustable, allowing dynamic repositioning to accommodate different article formats and nesting requirements. This dynamic capability enables the system to adapt to various space optimization needs without requiring complex fixed mechanisms.
3Adaptability or versatility
If the loading robot works with fixed row configurations, then the robot operation is simplified, but the ability to handle various formats especially odd number of rows is limited
Solution Approach 1:
The patent segments the loading process into two independent parts: the intermediate station handles article reception and positioning, while the loading robot focuses on transferring compacted articles to boxes. This segmentation allows each component to operate with simplified logic while collectively handling various formats including odd numbers of rows.
Solution Approach 2:
The intermediate station serves multiple functions: receiving articles from the inlet area, positioning them on support elements, compacting them into nested arrangements, and preparing them for loading. This multi-functionality enables the system to handle various article formats and configurations without requiring complex robot operations for each variation.
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
This solution enables the production of various formats that were previously unattainable with conventional machines, reducing costs and increasing flexibility, particularly beneficial for packaging coffee capsules and other tapered articles by allowing for optimal space utilization and format changes.
Implementation Method 1
a series of rods ending with vacuum-operated suction cups
Data Source
Figure 1~3
Figure 4~5
Figure 6~7
AI summary
Machine and method for cartoning articles (A) in containers or boxes, in which the machine has a loading section comprising an article inlet area (1); a loading area (2) for loading articles into said containers; a configuring device (3); at least a first robot (4) arranged to load articles from said inlet area (1) and transfer the articles to said configuring device (3); at least a second robot (5) arranged to pick up articles from said configuring device (3) and transfer them to said loading area (2), in which the configuring device (3) comprises an array of seats (302) for temporary accommodation of articles, and said array of seats (302) of the configuring device (3) is formed from rows of article-receiving seats having a variable transversal distance; said configuring device (3) operates in a synchronised manner with the first robot (4) and with the second robot (5) varying the relative position between respective rows of seats to provide interface respectively with the first robot and with the second robot.