Horizontal Conveyor Superposition for Layered Product Grouping
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Solution Overview
Problem
Existing packaging machines for forming groups of superposed layers, such as rolls of tissue paper, face challenges in achieving high speeds due to the complexity of their design and the need for elevator platforms, which slow down production and increase line complexity.
Innovation Solution
A method and machine that allow for the formation of groups of products with a variable number of superposed layers without the use of elevator platforms, by synchronizing the movement of layers along a principal direction of feed, using a series of conveyors oscillating about horizontal axes to superpose layers continuously, eliminating the need for accumulation on elevator platforms and simplifying the packaging line layout.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If elevator platforms are used to superpose layers, then the layers can be stacked vertically, but the production speed decreases and the machine complexity increases
Solution Approach 1:
The patent transitions from vertical stacking using elevator platforms to horizontal superposition where layers are fed side-by-side and then superposed in the horizontal direction. This dimensional change eliminates the need for vertical elevation mechanisms while achieving the same layer grouping function, thereby increasing production speed and reducing machine complexity.
Solution Approach 2:
The invention removes the elevator platform component entirely from the system. By extracting this unnecessary element and replacing it with a simplified conveyor-based superposition mechanism, the patent reduces device complexity and eliminates the speed limitations imposed by vertical lifting operations.
2Adaptability or versatility
If complex machine configurations are used to form multiple superposed layers, then the layer grouping can be achieved, but the machine structure becomes more complex
Solution Approach 1:
The patent employs universal conveyor components that can handle multiple functions: feeding layers horizontally, positioning them for superposition, and delivering the grouped layers. These multi-functional conveyors replace specialized complex mechanisms, enabling the machine to form groups with variable numbers of superposed layers while maintaining a simple overall structure.
Solution Approach 2:
The invention uses dynamic conveyor systems with adjustable speeds and positions that can adapt to different layer grouping requirements. This dynamic capability allows the machine to produce packs with variable numbers of superposed layers without requiring reconfiguration or additional complex structures, as the conveyors can be programmed to achieve the desired layer combinations.
Data Source
Figure 1A~2A
Figure 1B~2B
Figure 1C~2C
AI summary
There is described a machine for forming groups of ordered products, each group comprising products disposed according to superposed layers (S). The machine comprises a succession of conveyors (5, 9, 11) aligned according to a principal direction (T) of alignment, with a feed conveyor and a delivery conveyor. The feed conveyor (5) receives single layers of products aligned with and spaced from one another; and the conveyors are disposed and controlled so as to distribute layers of products on a predetermined number of levels at different heights, and to unload onto the delivery conveyor a predetermined number of layers, superposed on one another, equal to the predetermined number of said levels at different heights.