Container Orientation Apparatus Using Integrated Conveyor and Grippers
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Solution Overview
Problem
Existing systems for generating a continuous and ordered flow of containers with complex shapes are complex, expensive, and prone to inefficiencies due to the need for multiple independent machines and accumulation conveyors, which can lead to jamming and require lengthy setup processes.
Innovation Solution
A method and apparatus using dual feed transport systems and control means to detect container orientation and position, with a processor controlling gripping mechanisms to align and arrange containers into a continuous, ordered flow with consistent spacing and orientation, suitable for labeling, filling, and closing operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional sorting bowl systems with multiple independent machines and accumulation conveyors are used, then a continuous and ordered flow of containers can be achieved, but the system complexity and cost increase significantly
Solution Approach 1:
The patent merges the functions of multiple independent machines (sorting bowl, selection trays, star wheels, orientation wheels) into a single integrated apparatus. The conveyor belt system combines feeding, sorting, and orientation functions in one continuous process, eliminating the need for separate accumulation conveyors between machines and reducing overall system complexity while maintaining continuous flow reliability.
2Manufacturing precision
If multiple independent machines with accumulation conveyors are used, then container orientation can be achieved, but the space occupation increases
Solution Approach 1:
The patent performs container orientation in the longitudinal dimension of the conveyor belt rather than using separate lateral orientation machines. The sorting and orientation operations occur along the length of the single conveyor belt, eliminating the need for additional accumulation conveyors and reducing the overall footprint of the system while maintaining precise container orientation.
3Manufacturing precision
If sorting bowl systems with detection means and motorized spindles are used, then container positioning accuracy can be achieved, but the device complexity increases
Solution Approach 1:
The single conveyor belt system performs multiple functions (feeding, sorting, orienting, and positioning containers) that traditionally required separate machines. The integrated apparatus uses a unified control system with detection means that manages all positioning and orientation operations along the conveyor, reducing the number of independent control systems and motorized components while maintaining positioning accuracy.
4Productivity
If accumulation conveyors are added between machines, then discontinuous feed flow can be eliminated, but the setup complexity and downtime increase
Solution Approach 1:
The patent achieves continuous feed flow through a single integrated conveyor belt system that processes containers continuously from feeding to output without interruption. The unified system eliminates the need for accumulation conveyors and intermediate stopping points, allowing containers to move continuously through the apparatus while reducing setup complexity and minimizing downtime between container batches.
Data Source
AI summary
Method and apparatus for realizing a continuous and ordered flow (50) of containers (20), comprising the steps of:—providing a feed flow (30, 30′) of containers (20) arranged with the respective main axes (X-X) randomly oriented; detecting for each container (20) the position and the orientation of its main axis (X-X), and which of the two main faces (A, B) of the container lies on the transport surface (14, 14′); picking up (12, 12′) said containers (20) from said transport surface (14, 14′) and releasing said containers (20) in a first continuous and ordered output flow (40) in an advancing direction (MD), on a surface (18) of a first output transport system (15), wherein said containers are aligned, equidistant (P) from one another, with the respective main axes (X-X) parallel to each other and perpendicular to said advancing direction (MD), picking up (62) said containers (20) from said first continuous and ordered output flow (40), rotating the main axis X-X of each container (20) by 90° in a first direction, the containers which have a first main face (A) lying on the surface (18) of the first output transport system (15), and rotating in a second direction, opposite to the first direction, the containers that have a second main face (B) lying on the surface (18) of the output first transport system (15), and depositing (62) said containers (20) on a second output transport system (70), realizing a second continuous and ordered flow (50) in an advancing direction (MD″) wherein said containers (20) are aligned, equidistant from each other and with the respective longitudinal axes (X-X) perpendicular to the surface (72) of said second output transport system (70), with the filling openings (22) facing upwards and with the respective main faces (A, B) all oriented in the same direction.