Conveyor Synchronization for Damage-Free Cup Train Transfer
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Solution Overview
Problem
The existing methods for transporting cup trains between deep-drawing presses often result in deformations, damage, and synchronization issues due to high speeds and intermittent operation, leading to jams and manual intervention, especially when one press stops suddenly.
Innovation Solution
A conveyor device that maintains a free space between cup trains to accommodate additional products, synchronizes the speed and phase of the deep-drawing presses, and controls the conveyor to pick up the last product before a stop, ensuring seamless transfer and operation even during sudden stops.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If cup pulls are transported at high speed from the first deep-drawing press, then productivity is improved, but deformations and damage occur when they hit the tail end
Solution Approach 1:
The conveyor device dynamically adjusts its speed to match the incoming cup pulls, then gradually accelerates them to the target speed. This dynamic speed matching prevents sudden impacts and deformations while maintaining high productivity throughout the transport process.
Solution Approach 2:
The system prepares for speed transitions in advance by using a controlled acceleration zone where cup pulls are gradually sped up before joining the main conveyor flow. This cushioning approach prevents shock loads and product damage.
2Reliability
If the second deep-drawing press stops suddenly, then reliability is improved by allowing manual intervention, but synchronization is lost and manual removal of bottleneck jam is required
Solution Approach 1:
The conveyor device maintains continuous operation and keeps cup pulls in motion even when the second press stops. The buffered zone ensures that the conveyor never completely halts, preventing jams and eliminating the need for manual intervention to clear bottlenecks.
Solution Approach 2:
The system prepares for potential stops by maintaining a buffered zone with spare cup pulls already positioned on the conveyor. This preliminary positioning ensures that when the second press stops and restarts, cup pulls are immediately available without causing jams or requiring manual clearance.
3Manufacturing precision
If cup pull brakes are used to slow down cup pulls, then deformations are reduced, but cup pulls accelerate again and cause damage when hitting the end of the traffic jam
Solution Approach 1:
The invention removes the braking function entirely from the system. Instead of slowing cup pulls with brakes that cause subsequent acceleration and impact, the system uses a buffer zone to absorb speed differences and maintains continuous gentle propulsion, eliminating the root cause of surface damage.
4Reliability
If complex cup pull guides are equipped to prevent cup pulls from flying away, then reliability is improved, but device complexity and adjustment effort increase
Solution Approach 1:
The conveyor device uses the cup pulls themselves to guide and contain each other through their natural spacing and positioning on the belt. The system requires no additional complex guiding structures, as the cup pulls self-organize into stable positions during transport.
Data Source
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AI summary
The invention relates to a method for transporting production products from a first production machine to a second production machine by means of a conveying device, wherein the first and second production machines are operated intermittently, wherein the production products produced in the first production machine are fed to the conveying device, wherein the production products are taken along by the conveying device and forced along the conveying path of the conveying device to the speed of the conveying device and the production products are fed to the second production machine intermittently by means of the conveying device.