Defective Workpiece Discharging Device for Absorbent Articles
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Solution Overview
Problem
Existing defective-workpiece discharging devices for absorbent articles, such as disposable diapers, face challenges in accurately discharging defective items and the adjacent conforming items due to timing issues related to the conveyance pitch and placement of sensors, leading to potential discharge failures.
Innovation Solution
A defective-workpiece discharging device that includes a first and second conveyance path, a sorting mechanism, defect detection sensors, and a passage detection sensor, where the controller discharges not only the defective item but also adjacent items on both the upstream and downstream sides, ensuring all defective items are caught and discharged by positioning the passage detection sensor at a distance greater than or equal to the conveyance pitch from the end of the first conveyance path.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If the passage detection sensor is positioned close to the sorting mechanism to enable timely detection, then the response time is improved, but the accuracy of discharging adjacent workpieces deteriorates because the sensor may miss detecting workpieces that have already passed
Solution Approach 1:
The passage detection sensor is positioned upstream at a distance of at least one conveyance pitch from the sorting mechanism, allowing the system to detect workpieces before they reach the sorting point. This preliminary detection enables the controller to prepare the sorting mechanism in advance, ensuring both timely response and accurate discharge of defective workpieces along with their adjacent counterparts.
2Productivity
If the conveyance pitch is reduced to increase production capacity, then the productivity is improved, but the difficulty of detecting and measuring workpiece position increases
Solution Approach 1:
The passage detection sensor acts as an intermediary detection point between the workpiece source and the sorting mechanism. By positioning this sensor at a standardized distance (one conveyance pitch) upstream, the system creates a reliable reference point for detecting workpiece passage regardless of the actual conveyance pitch value, thereby maintaining detection accuracy while allowing flexible productivity adjustments.
Data Source
Figure 1
Figure 2A~2B
Figure 3A~3B
AI summary
Provided is a defective-workpiece discharging device that discharges a workpiece having a defect to a discharge path from a conveyance path that conveys a plurality of workpieces relating to absorbent articles in a conveyance direction at a predetermined conveyance pitch. The conveyance path has a first conveyance path and a second conveyance path that is located downstream from the first conveyance path. The defective-workpiece discharging device includes: a sorting mechanism that is provided between the first conveyance path and the second conveyance path, and that sorts the workpieces into either one of the second conveyance path and the discharge path, the workpieces having passed the first conveyance path; a defect detection sensor that detects the defect and outputs a defect detection signal, a passage detection sensor that is provided on the first conveyance path, and that detects passage of the workpieces at a predetermined position on the first conveyance path and outputs a passage detection signal; and a controller that controls a sorting operation of the sorting mechanism, based on the defect detection signal and the passage detection signal. An end of the first conveyance path on the sorting mechanism side and the predetermined position are separated by a distance greater than or equal to the conveyance pitch.