Cup Insertion Mechanism for Dual-Compartment Containers
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
There is a need to automate the cost-effective and reliable insertion of cup-shaped inserts into containers to create dual-compartment assemblies, particularly for self-heating or self-cooling containers, where the existing methods are inefficient and prone to errors.
Innovation Solution
An automated apparatus and method involving a container conveyor, an insert conveyor, and an inserter system that synchronizes the movement of containers and inserts, using a self-timing wheel, tip-over mechanism, and pneumatic cylinders to ensure precise and efficient insertion of cup-shaped inserts into containers, with sensors for detecting jams and abnormalities to prevent errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual insertion methods are used, then flexibility and adaptability are maintained, but productivity is low and manufacturing precision is poor
Solution Approach 1:
The apparatus is divided into distinct functional modules: a container conveyor system for transporting containers, an insert conveyor system for supplying inserts, and an inserter mechanism for performing the insertion. Each module operates independently but coordinates through synchronization signals, allowing the system to achieve high productivity while maintaining manageable complexity through modular design
Solution Approach 2:
The patent replaces manual mechanical insertion operations with an automated insertion mechanism that uses controlled mechanical movement. The inserter mechanism automatically positions and inserts cups into containers without manual intervention, significantly increasing production rate while the modular mechanical design keeps the overall system complexity manageable
2Volume of stationary object
If inserts are conveyed in inverted orientation, then space utilization is improved, but reliability decreases due to potential shingling and jamming
Solution Approach 1:
The insert conveyor employs a star wheel mechanism that periodically rotates to advance inserts one by one. This periodic rotational action creates controlled intervals between insert movements, preventing shingling and interlocking while maintaining the space-efficient inverted orientation. The star wheel's discrete positioning ensures reliable, jam-free transport
Solution Approach 2:
The star wheel acts as an intermediary mechanism between the insert conveyor and the inserter. It mediates the transfer of inserts by providing a controlled, periodic advancement mechanism that prevents direct contact and potential jamming between inserts, while still achieving reliable delivery to the insertion point
3Manufacturing precision
If synchronization mechanisms are added to coordinate containers and inserts, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The apparatus incorporates sensors that detect the presence and position of both containers and inserts. This feedback information is used by the control system to synchronize the conveyor systems and inserter mechanism, ensuring precise alignment and placement. The feedback loop maintains manufacturing precision without requiring overly complex mechanical synchronization mechanisms
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
The system enables efficient, reliable, and cost-effective production of container assemblies with cup-shaped inserts, reducing human error and increasing production rate by ensuring each insert is correctly placed within the container, thus enhancing the manufacturing process for dual-compartment containers.
Implementation Method 1
The tip-over mechanism can include an air nozzle for delivering a blast of air against the lead insert to cause the insert to tip over. The tip-over mechanism can also include a solenoid valve or the like that is activated to supply pressurized air to the air nozzle
Data Source
AI summary
An apparatus and method for producing container assemblies having a cup-shaped insert disposed within a container. A container conveyor conveys a series of open containers along a lower horizontal path, the container conveyor bringing each container in turn to a stop at an insertion station. A generally vertical inserter chute is disposed above the insertion station for conducting a generally cup-shaped insert through the inserter and out the lower end into a container positioned at the insertion station. An insert conveyor disposed above the inserter conveys a series of inserts along an upper horizontal path, each insert on the insert conveyor having an open end and an opposite closed end and being in an inverted orientation such that the open end of the insert faces downward. A lead one of the inserts being conveyed on the insert conveyor tips over and falls into the inserter in an upright orientation.