Conveyor Star-Wheel with Alternating Holders for Rapid Size Change-Over
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Solution Overview
Problem
Existing conveyor systems for rotary carousels require time-consuming and complex size change-over operations due to the need for different star-wheels and mechanical adjustments, impacting productivity, especially when processing containers of varying sizes and shapes.
Innovation Solution
A conveyor system with a single conveyor belt and screw feeder coupled with transfer star-wheels featuring alternating holder types and an electronic control unit for independent motor control, allowing for rapid size change-over without altering star-wheels or mechanical transmissions, and enabling synchronization with the carrousel and screw feeder.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If different star-wheels are used for different container sizes, then the conveyor can accommodate various container dimensions, but the size change-over operation becomes time-consuming and complex
Solution Approach 1:
The patent applies a single star-wheel design with multiple holder types (first type and second type holders) that can accommodate different container sizes. The electronic control unit enables this universal star-wheel to be selectively operated in different modes (first operational mode for first type holders, second operational mode for second type holders), eliminating the need for physical star-wheel changes while maintaining adaptability to various container dimensions.
Solution Approach 2:
The patent implements dynamic operational modes where the electronic control unit can switch the star-wheel between different operational states. The star-wheel dynamically adjusts its function by operating in a first mode when first type holders are positioned at the transfer point, and in a second mode when second type holders are positioned, allowing rapid adaptation without mechanical reconfiguration.
2Adaptability or versatility
If star-wheels are removed and substituted for size change-over, then the conveyor can be adapted to new product dimensions, but the operation becomes complex requiring mechanical transmission modifications
Solution Approach 1:
The single star-wheel is designed with multi-functionality to handle both first type and second type holders for different container sizes. The electronic control unit provides universal control for both holder types, eliminating the need for complex mechanical transmission modifications when changing product sizes.
Solution Approach 2:
The patent replaces the mechanical system of physical star-wheel substitution with an electronic control system. The electronic control unit receives signals and automatically switches between operational modes, replacing the need for manual mechanical operations of removing and installing different star-wheels.
3Adaptability or versatility
If multiple star-wheels are used for different sizes, then container size variability is handled, but productivity decreases due to frequent change-overs
Solution Approach 1:
The star-wheel operates dynamically with switchable operational modes controlled electronically. The system can rapidly transition between first operational mode and second operational mode based on the container type being processed, maintaining high productivity without the downtime associated with physical star-wheel changes.
Solution Approach 2:
The electronic control unit replaces the mechanical change-over process, enabling rapid switching between holder types through electronic signals rather than physical star-wheel substitution. This significantly reduces change-over time and maintains production productivity.
4Adaptability or versatility
If star-wheels are frequently changed for size adaptation, then the conveyor can process different products, but production downtime increases
Solution Approach 1:
The single star-wheel with multiple holder types and electronic control provides universal processing capability for different products. The electronic control unit enables immediate switching between operational modes, eliminating production downtime associated with physical star-wheel changes.
Solution Approach 2:
The electronic control system replaces the mechanical star-wheel change-over process, allowing instantaneous mode switching through electronic signals. This substitution eliminates the time-consuming mechanical operations and significantly reduces or eliminates production downtime during product transitions.
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
Facilitates fast and efficient size change-over operations with a simplified mechanical structure, reducing production downtime and costs, while maintaining synchronization with the carrousel and conveyor belt speeds to prevent container damage.
Implementation Method 1
there are also spacing means for spacing the containers at a predetermined distance from each other... the spacing means comprise a screw feed rotating about an axis of rotation which is parallel with the direction of feed of the conveyor belt
Implementation Method 2
a first transfer star-wheel designed to transfer the containers which have arrive close to the infeed station to the carrousel... Each star-wheel is mounted on its own supporting shaft and can rotate about the axis of rotation defined by it
Implementation Method 3
The containers to be processed (for example bottles) are carried to the carrousel by a first conveyor belt which runs in the direction of an infeed station
Data Source
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AI summary
A conveyor (1) for containers (2), such as bottles, to be processed and for processed containers (2) for operating machines of the type with a rotary carrousel (3), comprises at least one transfer star-wheel able to rotate about an axis of rotation, for picking up one container (2) at a time from an infeed station (4) and bringing it to a carrousel (3), and for picking up a processed container (2) from the carrousel (3) and bringing it to an outfeed station (6). The edge of each star- wheel forms a plurality of holders (17) for accommodating each container (2). According to this invention the holders (17) of each transfer star-wheel form an alternating sequence, along the edge of the star-wheel, of at least two different types (19), (20) of holders (17). There being the possibility of coupling the conveyor (1) with an operating machine carrousel (3) for feeding to the carrousel and picking up from it at least two types (19), (20) of containers (2) differing in their shape and/or dimensions which can be accommodated respectively in a first and second type of the holders (17). This invention also relates to an operating machine for processing containers (2), such as bottles, comprising a rotary carrousel (3) and a conveyor (1) of the type defined above.