Dynamic Conveyor Brackets for Foil Wrapping Stability
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Solution Overview
Problem
Existing packaging systems face challenges in stabilizing non-cuboid beverage cartons during wrapping, leading to production standstills and increased costs due to frequent over-turning and high film requirements, as well as inefficiencies in the wrapping process and space constraints.
Innovation Solution
A device with a conveyor belt system featuring two brackets that rotate at the same speed as the conveyor belt to support the cartons, and a third bracket that wraps the film at a higher speed, allowing for independent control and acceleration, reducing the need for a longer conveyor line and enabling efficient wrapping of containers of varying sizes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If support brackets are placed on products and the container is wrapped with foil using a third bracket, then falling over can be prevented, but a correspondingly longer conveyor line is necessary and only two wrapping tracks can be arranged directly next to one another
Solution Approach 1:
The first and second brackets are made dynamically controllable with independent drives, allowing them to be accelerated briefly to match the position of the third bracket. This dynamic adjustment eliminates the need for a longer conveyor line, as the brackets can synchronize their positions on the fly rather than requiring fixed spacing throughout the entire conveyor length.
Solution Approach 2:
The speed parameter of the first and second brackets is changed temporarily through acceleration, allowing them to catch up with or match the position of the third bracket. This parameter change enables flexible positioning without being constrained by the fixed conveyor speed, thereby reducing the required conveyor line length.
2Loss of substance
If the film is wound tightly to reduce film requirement per container, then film consumption is reduced, but frictional forces acting on the bracket become high causing disruptions
Solution Approach 1:
The third bracket is made dynamically controllable with its own drive, allowing it to accelerate independently of the conveyor belt. This enables the bracket to apply wrapping force more efficiently and release it controllably, reducing the frictional forces that would otherwise cause disruptions while maintaining tight film winding to reduce consumption.
3Stability of the object's composition
If the first and second brackets rotate at the same speed as the conveyor belt, then products are effectively supported against falling over, but the wrapping process takes more time
Solution Approach 1:
The first, second, and third brackets are all equipped with independent drives, allowing them to dynamically adjust their speeds. The first and second brackets can rotate at conveyor speed for stable product support, while the third bracket can accelerate independently to complete the wrapping operation faster, thus maintaining productivity without compromising stability.
Data Source
Figure 1a
Figure 1b
Figure 2
AI summary
The device has clamps (7a, 7b) provided to circle a conveyor belt (6) on a path, where the path is identical for both the clamps. The clamps are respectively connected with a pair of traction units (13, 14). The clamps descend laterally downward before a third clamp that is behind the conveyor belt, where packages (G1, G2) are laid at the clamps (7a, 7b) that are accelerated in a short-run manner. The packages are assembled from a number of packaged products (P) such as beverages or flour packed in bags. An independent claim is also included for a method for stamping a number of packages in a foil.