Dual Carousel Carton Loading to Reduce Article Breakage
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Solution Overview
Problem
Existing packaging systems face challenges in efficiently loading articles, such as beverage containers, into cartons at high speeds while maintaining efficiency and minimizing breakage.
Innovation Solution
A dual carousel system comprising a carton opening carousel and a carton loading carousel, equipped with guide assemblies and loading lug assemblies, that facilitates the partial opening and orientation of cartons, followed by precise placement of articles into carton compartments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high-speed loading is implemented, then productivity increases, but article breakage increases
Solution Approach 1:
The patent applies beforehand cushioning by providing a cushioning surface in the carton receiving area that is compliant and capable of absorbing impact energy. This cushioning surface is positioned to receive articles before they are fully loaded, preventing breakage during high-speed operation by dissipating forces before they reach the final destination.
Solution Approach 2:
The patent changes the physical parameters of the receiving area by providing a compliant cushioning surface with specific mechanical properties. This cushioning surface has controlled hardness and elasticity to absorb impact during high-speed loading, transforming the rigid receiving environment into a more forgiving one that prevents article breakage while maintaining loading speed.
2Productivity
If dual carousel system is used, then loading efficiency improves, but device complexity increases
Solution Approach 1:
The patent merges the carton opening function and the loading function into a single integrated dual carousel system. The first carousel opens cartons and positions them, while the second carousel loads articles into the same cartons. This merging of functions into one coordinated system improves loading efficiency while avoiding the complexity of entirely separate systems.
Solution Approach 2:
The patent applies preliminary action by having the first carousel perform carton opening and positioning operations before the second carousel begins the loading process. This preliminary preparation of cartons ensures they are ready for immediate loading, improving overall efficiency while distributing tasks across the two carousels in a coordinated manner.
3Loss of time
If cartons are opened while moving, then processing time is reduced, but manufacturing precision decreases
Solution Approach 1:
The patent applies periodic action by using the rotational movement of the carousels to periodically present cartons to opening mechanisms at precise intervals. The carousels rotate to bring cartons to specific positions where opening occurs, then continue rotating to present them again at the next loading position. This periodic presentation maintains precision while enabling continuous motion operation.
Solution Approach 2:
The patent embraces dynamics by performing carton opening operations while the carousels are in motion rather than stopping the system. The opening mechanisms are positioned to engage cartons during their rotational travel, and the system is designed to maintain precise positioning and opening accuracy despite the continuous movement of the carousels.
Data Source
AI summary
A method of loading articles in cartons. The method can comprise moving a carton in a generally flat configuration in a downstream direction with a carton opening carousel, at least partially opening the carton while moving the carton with the carton opening carousel, and transferring the carton from the carton opening carousel to a carton loading carousel in a transfer region. The transferring the carton can comprise moving the carton in an upstream direction. The method further can comprise loading a plurality of articles into the carton while moving the carton in a downstream direction with the carton loading carousel.