Conveyor Belt Defective Product Rejection Mechanism
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Solution Overview
Problem
Existing methods for rejecting defective cut web products on high-speed production lines are inefficient due to space requirements, noise, dust creation, and inaccuracy, and often necessitate additional expensive equipment like pneumatic air blasts, vacuums, or mechanical switches.
Innovation Solution
A method and apparatus that uses a folding device with a tucker and driver to selectively fold or redirect cut web products by slowing or stopping the folding process for defective products, eliminating the need for a reject gap and utilizing existing conveyor system infrastructure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If pneumatic air blasts are used to reject defective cut web products, then defective products can be diverted from the stream of satisfactory products, but excessive space is required for the pneumatic device and reject gap, and excessive dust and noise are created
Solution Approach 1:
The patent combines the rejection function with the existing conveyor system by using the conveyor belt itself to redirect defective products. The controller selectively activates conveyor sections to divert defective products into a reject bin, eliminating the need for separate pneumatic devices and reject gaps, thus resolving the space consumption issue while maintaining rejection accuracy
Solution Approach 2:
The patent replaces the pneumatic air blast system with a mechanically controlled conveyor system. Instead of using compressed air to divert products, the system uses controlled movement of conveyor belt sections to redirect defective products, eliminating dust and noise associated with pneumatic systems while maintaining effective product rejection
2Reliability
If vacuum devices are used to remove defective cut web products, then defective products can be removed from the stream of quality products, but large amounts of space are required for the vacuum device and reject gap, and excessive noise is created
Solution Approach 1:
The patent integrates the removal function into the existing conveyor system rather than using separate vacuum devices. The controller selectively stops or redirects conveyor sections carrying defective products into a reject bin, eliminating the need for dedicated vacuum equipment and associated space while maintaining accurate defective product removal
Solution Approach 2:
The patent replaces the vacuum-based removal system with a mechanically controlled conveyor system. Instead of using vacuum suction to remove products, the system uses controlled conveyor belt movement to redirect defective products, reducing noise and eliminating the need for large vacuum equipment while maintaining effective removal accuracy
3Reliability
If mechanical switches are used to divert defective cut web products, then defective products can be diverted to an alternative pathway, but excessive space is required for the switches and alternate pathway
Solution Approach 1:
The patent combines the diversion function with the existing conveyor system by using the conveyor belt itself to redirect defective products. The controller selectively activates or deactivates conveyor sections to guide defective products into a reject bin, eliminating the need for separate mechanical switches and alternate pathways, thus resolving the space consumption issue while maintaining diversion accuracy
Solution Approach 2:
The patent replaces traditional mechanical switch systems with a electronically controlled conveyor system. Instead of using physical switches that pop up to divert products, the system uses controlled conveyor belt movement to redirect defective products, eliminating the need for additional mechanical components and associated space while maintaining accurate product diversion
4Reliability
If pneumatic air blasts or mechanical switches are used to reject defective products, then defective products can be removed from the stream, but additional expensive equipment is required
Solution Approach 1:
The patent makes the existing conveyor system multi-functional by enabling it to perform both its primary function of transporting products and the secondary function of rejecting defective products. The controller selectively activates different conveyor sections to either transport or redirect products, eliminating the need for dedicated rejection equipment and reducing overall system complexity and cost
Solution Approach 2:
The patent enables the conveyor system to reject defective products using its own components and control mechanisms. The existing conveyor belt and motor system are controlled to redirect defective products, eliminating the need for separate rejection equipment and reducing overall system complexity and cost
Data Source
AI summary
The present disclosure relates to a method for redirecting cut web products and/or rejecting cut web products. The method comprises advancing a plurality of cut web products along a first path and providing a redirecting or folding device for folding the plurality of cut web products and/or delivering the folded cut web products to a second path. Prior to reaching the folding device, the cut web products may be determined to be defective. The folding device can be accelerated, decelerated, or substantially stopped, such that a selected cut web product is not delivered to the second path, thereby rejecting the selected cut web product. The present disclosure additionally comprises an apparatus for redirecting and/or rejecting cut web products.