Dynamic Outsert Application System for Continuous Conveyor Processing

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Solution Overview

Problem

Existing outsert application systems face challenges in efficiently and continuously applying outserts of different thicknesses and widths to containers without requiring frequent system modifications or stopping conveyor movement.

Innovation Solution

A system incorporating a vacuum assembly with a pivot arm that rotates about two axes, allowing for the translation of the vacuum assembly to match the speed and direction of containers, facilitating the engagement and application of outserts from a hopper to containers, and utilizing a cam device or linear actuator for precise movement and alignment.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If a rotary pick and place mechanism with multiple vacuum arms is used to apply outserts, then outserts can be applied to containers, but the vacuum arms cannot match the speed and direction of the containers and cannot effectively process thick outserts

Engineering Contradiction:

Improveoutsert application capabilityVSAvoidability to match container speed and process thick outserts

Core Design Contradiction:

ProductivityVSAdaptability or versatility

Solution Approach 1:

The patent employs a dynamic application mechanism where the outsert application head can move with the containers on the conveyor belt, matching their speed and direction. This dynamic positioning allows the system to effectively process both thin and thick outserts by adjusting the application timing and position, eliminating the limitations of fixed rotary vacuum arm mechanisms.

Inventive Principle:

Principle #15Dynamics

2Ease of operation

If an intermediate transfer assembly is used to transfer outserts from J-chute to turret, then outserts can be transferred between devices, but the system complexity and cost increase

Engineering Contradiction:

Improveoutsert transfer capabilityVSAvoidnumber of transfer devices

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The patent combines the outsert storage, transfer, and application functions into a single integrated system. The application head directly receives outserts from the conveyor and applies them to containers without requiring separate intermediate transfer assemblies, turrets, or spindle arms, thereby reducing system complexity while maintaining operational effectiveness.

Inventive Principle:

Principle #5Merging (Combining)

3Adaptability or versatility

If different star wheel assemblies are used for outserts of different widths, then outserts of different sizes can be accommodated, but the system requires multiple assemblies and modifications

Engineering Contradiction:

Improveability to handle different outsert sizesVSAvoidnumber of star wheel assemblies

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent employs a universal application mechanism that can accommodate outserts of varying widths and thicknesses without requiring different star wheel assemblies. The system uses adjustable positioning and a flexible application head that adapts to different outsert dimensions, eliminating the need for multiple specialized components and simplifying system configuration.

Inventive Principle:

Principle #6Universality (Multi-functionality)

4Productivity

If the conveyor is stopped momentarily to apply multiple outserts to containers, then outserts can be applied to a set of containers, but the conveyor movement must be stopped which is undesirable

Engineering Contradiction:

Improvebatch outsert application capabilityVSAvoidconveyor stoppage time

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The patent enables continuous outsert application by synchronizing the application head movement with the continuously moving containers on the conveyor. The system applies outserts to multiple containers in sequence without stopping the conveyor, maintaining continuous production flow while efficiently applying outserts to sets of containers through coordinated timing and positioning.

Inventive Principle:

Principle #20Continuity of useful action

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

Enables continuous and efficient application of outserts of varying thicknesses and widths without stopping the conveyor, reducing complexity and cost by matching the velocity of the outserts with the containers and accommodating different sizes without requiring multiple star wheel assemblies or feed screw replacements.

Implementation Method 1

a vacuum assembly for accommodating passage of a vacuum to an engagement surface at a first end thereof for engaging an outsert

Methodology Applied

Scientific EffectVacuum: Vacuum

Data Source

PatentUS9150324B2Systems and methods for dynamically applying outserts to articles

Publication Date: 2015.10.06 NJM PACKAGING INC

AI summary

An outsert application system is disclosed that includes a vacuum assembly and a pivot arm. The vacuum assembly is for accommodating passage of a vacuum to an engagement surface at a first end thereof for engaging an outsert. The pivot arm is rotatably coupled at a first end thereof to a second end of the vacuum assembly, and the vacuum assembly is adapted to rotate with respect to the pivot arm about a first axis. A second end of the pivot arm is adapted for rotation about a second axis that is substantially parallel with the first axis. The system further includes a translation device that causes the first axis to move with respect to the second axis as the vacuum assembly rotates about the first axis.