Container Group Aligning Device with Metering Belt Control
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Solution Overview
Problem
Existing packaging and palletizing systems face challenges in gently handling packs, leading to rough impacts and inefficiencies in forming precise rows and layers for pallets, due to speed differences and frictional resistance between conveyor belts, resulting in gaps and increased processing time.
Innovation Solution
A device comprising an allocating belt, a conveyor belt, and a layer-forming belt, each with its own motor, controlled by a programmable controller to maintain constant speeds and precise gap formation using light barrier sensors and cam disc control, allowing for reliable, quick, and high-quality assembly of cycles with predefined gaps, and assisted by robots for orientation and transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If packs are transferred between conveyor belts with different speeds, then gap formation between packs is achieved, but rough impact and frictional resistance occur causing twisting and handling errors
Solution Approach 1:
The patent introduces an intermediary zone between conveyor belts where packs are gradually accelerated or decelerated using a frictionless magnetic field. This mediator zone eliminates direct mechanical contact that causes rough impact and twisting, while still achieving the required speed transition for precise gap formation between packs.
Solution Approach 2:
The patent replaces the traditional mechanical friction-based speed transition system with a magnetic field-based system. Packs are accelerated or decelerated through magnetic forces without physical contact, eliminating frictional resistance and twisting while maintaining precise control over gap formation between packs.
2Manufacturing precision
If multiple conveyor belts with different speeds are used to form rows, then pack alignment is achieved, but device complexity increases
Solution Approach 1:
The patent makes a single conveyor belt multi-functional by equipping it with both friction-based and frictionless magnetic zones. This universal belt can perform both traditional mechanical conveying and precise magnetic acceleration/deceleration, eliminating the need for separate conveyor belts for different functions while maintaining high alignment precision.
Solution Approach 2:
The patent merges the functions of multiple conveyor belts into a single integrated system. By combining mechanical conveying and magnetic speed control in one belt, the system reduces the number of separate components needed while achieving the same pack alignment precision that previously required multiple belts.
3Manufacturing precision
If friction-based speed control is used between conveyor belts, then gap formation is achieved, but processing time increases due to gaps during transfer
Solution Approach 1:
The patent ensures continuous operation by using magnetic fields to smoothly accelerate or decelerate packs during transfer between zones. This eliminates stopping and starting that creates gaps in production, allowing continuous flow while maintaining precise gap formation between packs through controlled magnetic speed adjustment.
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 ensures accurate gap formation between packs, reduces twisting and friction, and enhances efficiency by eliminating gaps during transfer, resulting in faster pallet creation with improved pack alignment and reduced handling errors.
Implementation Method 1
Sensors are also provided which determine the position and/or location of the articles being transported on the surface of the conveyor belt
Data Source
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AI summary
A method and a device (1) for assembling and aligning containers (21) or groups of containers (23) are disclosed. The device (1) comprises at least one metering belt (3) and at least one conveyor belt (5). A control system (12) is provided which controls at least the speed of the metering belt (3) in order to divide the containers (21) and/or groups of containers (23) transported edge-to-edge on the metering belt (3) into several cycles (20) of containers (21) and/or groups of containers (23) on the conveyor belt (5). The cycles (20) are spaced apart from each other by a predefined gap (D).