Dual Collector Case Packing Method for Continuous Product Grouping
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Solution Overview
Problem
Existing product grouping methods for case packing, such as those described in document FR 2 918 359, face inefficiencies due to discontinuous collector movements that cause incidents and limit speed, primarily because the infeed conveyor has continuous movement while the collector has sequential, high-speed movements with accelerations, leading to dead time and equipment stress.
Innovation Solution
A method and machine that utilize a pair of rectilinear comb collectors moving transversely to collect products on an infeed conveyor, with one collector taking over from the other to maintain continuous operation, reducing speeds and accelerations, and featuring a looped movement for efficient product transfer and collection, controlled by sensors for optimal timing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single collector is used to collect products on an infeed conveyor, then the device structure is simple, but dead time occurs during the return movement which limits collecting speed
Solution Approach 1:
The single collector is divided into two separate collectors that operate in sequence. The first collector collects products and transfers them to the removal station, then returns to its starting position. While the first collector is returning, the second collector begins collecting products. This segmentation eliminates dead time by ensuring that collection operations continue uninterrupted during return movements.
2Productivity
If the collector moves at high speeds with complex accelerations to keep up with continuous infeed conveyor, then collecting efficiency is improved, but equipment stress increases and incidents occur
Solution Approach 1:
The system uses periodic, rhythmic movements for the collectors rather than continuous high-speed operations. Each collector follows a standardized cycle: collect products at a controlled speed, transfer to removal station, and return to starting position. This periodic action allows for controlled accelerations and decelerations, reducing equipment stress while maintaining steady productivity through the coordinated operation of two collectors.
3Loss of time
If the collector movement is synchronized with continuous infeed conveyor, then dead time is eliminated, but movement complexity increases
Solution Approach 1:
The complex synchronization problem is solved by segmenting the collection function into two independent collectors. Each collector operates with a simple, identical movement pattern: collect, transfer, and return. The coordination between collectors is managed through a control system that triggers the second collector to begin collection when the first collector starts its return movement, eliminating dead time without requiring complex continuous synchronization.
Data Source
AI summary
The invention relates to a method for grouping together products that arrive in line and are spaced apart from each other on an infeed conveyor (2), consisting of: collecting the products on the fly by means of a pair of collectors (4) that move transversely relative to the products on said conveyor (2); moving the products collected by collector (4A) to a removal station (11) and, at the same time, replacing said collector (4A) with the second collector (4B) that, in turn, collects the products; and dropping off the products from collector (4A) to the removal station (11) and bringing said collector (4A) back to a collecting position while intersecting collector (4B). The equipment includes a pair of carriages (7), each of which has a collector (4), said carriages being moved transversely and said collectors (4) being mounted on actuators (12) that move the collectors so as to transfer the latter from the removal position to a retracted position that makes it possible for said collectors (4) to intersect one other.