Thermoforming Stacker With Dual Containers for Continuous Output
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Solution Overview
Problem
Existing thermoforming processes face challenges in continuously transferring thermoformed items from a press to an output device without interrupting the production cycle, particularly when using multiple containers due to limited storage capacity and the need for items to be transferred between containers.
Innovation Solution
A stacker system with two horizontally aligned containers and a transfer device controlled by three axes, allowing items to be selectively loaded into either container, enabling uninterrupted stacking and transfer to an output device.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If two containers are vertically arranged one above the other for continuous stacking, then the production continuity is improved, but the storage capacity is limited particularly when items have considerable height and stacking pitch
Solution Approach 1:
The patent transitions from vertical stacking arrangement to horizontal alignment of containers. The first and second containers are positioned side-by-side in the horizontal direction rather than one above the other, allowing the transfer device to move between containers horizontally. This dimensional change increases storage capacity while maintaining production continuity, as the transfer device can efficiently alternate between horizontally positioned containers without the space constraints of vertical arrangement.
2Device complexity
If a single container is used for stacking, then the device complexity is reduced, but the production capacity is affected because the press must wait during transfer to the output device
Solution Approach 1:
The patent divides the stacking function into two separate containers (first container and second container) that operate independently. While one container is being filled with thermoformed items, the other container is being emptied to the output device. This segmentation allows parallel operations, eliminating waiting time and maintaining high production capacity without significantly increasing overall system complexity.
Solution Approach 2:
The patent implements continuous operation by ensuring that while one container is receiving items from the press, the other container is simultaneously delivering items to the output device. The transfer device alternates between containers without idle time, maintaining continuous useful action throughout the stacking process and maximizing production capacity.
3Productivity
If two containers are used for continuous stacking, then the production continuity is improved, but the transfer device complexity increases requiring control according to additional axes
Solution Approach 1:
The patent positions containers horizontally rather than vertically, which simplifies the transfer device control. The transfer device needs to move between horizontally aligned containers using transverse translation along with axial displacement and rotation, which is more straightforward than managing vertical positioning and switching. This horizontal arrangement maintains production continuity while reducing control complexity compared to vertical arrangements.
Data Source
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AI summary
A stacker for a thermoforming machine comprising two containers (100, 200) for stacking thermoformed items, each container being displaceable between a stacking location (101, 201) where the container is loaded with the thermoformed items by a transfer device (10), and a delivery location where the container feeds the items to an output device (300), wherein said transfer device (10) is controlled independently according to three axes including an axis of translation (III) to align the transfer device selectively with the stacking location of the first container (100) or of the second container (200).