Conveyor Assembly for Flat Baking Product Orientation
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Solution Overview
Problem
Existing conveyor systems for orienting and grouping flat baking products are inefficient, requiring expensive and inflexible industrial robots, which complicate line changes and increase footprint, and struggle to adapt to different packaging types and speeds.
Innovation Solution
A conveyor assembly with a first conveying device for forming partial stacks and a second conveying device driven by a linear motor, using individually controlled carrier members and a forming plate with grooves to adjust orientation and positioning, allowing for quick and reliable adaptation to various packaging configurations without the need for complex robot reconfiguration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If industrial robots are used to orient and group flat baking products, then the products can be oriented and grouped correctly, but the device complexity and cost increase significantly
Solution Approach 1:
The system divides the orientation and grouping process into two separate stages: first, a simple conveying device forms partial stacks of products; second, a forming plate with grooves completes the grouping and orientation. This segmentation eliminates the need for complex industrial robots while achieving the same functional result through divided, simpler operations.
Solution Approach 2:
The forming plate with grooves acts as an intermediary device between the partial stacks and the final packaged product. The grooves guide and orient the partial stacks into the correct configuration without requiring complex robotic manipulation, thereby simplifying the overall system while maintaining reliability.
2Extent of automation
If industrial robots are used for orientation and grouping, then product handling is automated, but the footprint and floor area usage increase
Solution Approach 1:
The first conveying device and the forming plate are merged into a compact integrated system that performs both partial stacking and final grouping in close proximity. This merging eliminates the need for large robotic workspaces while maintaining full automation of the orientation and grouping process.
3Extent of automation
If industrial robots are used for orientation and grouping, then production flexibility is reduced, but automation level is high
Solution Approach 1:
The system uses adjustable and reconfigurable components, including the forming plate with adjustable grooves and the first conveying device with variable parameters. This dynamic design allows quick adaptation to different product types, packaging requirements, and production volumes without complex robotic reprogramming, maintaining high automation while improving versatility.
4Reliability
If complex robot systems are used, then orientation and grouping can be achieved, but line changeover becomes complicated and time-consuming
Solution Approach 1:
The first conveying device pre-forms partial stacks with correct initial orientation before the products reach the forming plate. This preliminary action reduces the complexity of the final grouping step and enables rapid changeover when product specifications change, as the pre-stacking mechanism can be quickly adjusted without affecting the entire system.
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
Enables high-speed, flexible, and cost-effective orientation and grouping of flat baking products, simplifying line changes and increasing throughput by integrating the second conveying device with the packaging machine, reducing the need for additional transfers and synchronization.
Implementation Method 1
the second conveying device (108) is driven by a linear motor and is provided with a plurality of individually driven conveying fingers or carrier members
Data Source
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AI summary
The present invention provides a conveyor assembly for orienting and grouping together flat baking products for the purpose of packaging stacks or rolls of flat baking products by a packaging machine, the conveyor assembly at least comprising a first conveying device, a first transfer device, a forming plate and a second conveying device, wherein the first conveying device is configured to receive the plurality of flat baking products from a supply in a supply pattern, wherein the flat baking products, in the supply pattern, have a flat orientation with regard to the conveying plane of the first conveying device, and wherein the first conveying device is configured to form partial stacks of flat baking products from the plurality of flat baking products; the first transfer device is configured to simultaneously transfer a group of partial stacks into the forming plate; the forming plate comprises a number of parallel grooves which corresponds to the groups of partial stacks and is configured to form one or more stacks or rolls of flat baking products by moving the groups of partial stacks through the grooves; the second conveying device is configured to receive the stacks or rolls of flat baking products from the forming plate and transport the stacks or rolls of flat baking products to the packaging machine, and wherein the second conveying device is furthermore configured to adjust the intermediate distance and speed of stacks or rolls of flat baking products, wherein the intermediate distance and speed are determined by the packaging machine.