Dynamic Packaging Grouping and Cutting for Variable Bundle Sizes
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Solution Overview
Problem
Existing methods for producing layers of bundles with different sizes and numbers of articles or containers are inefficient, leading to suboptimal use of pallet space and requiring separate processes for each size variation.
Innovation Solution
A device and method that utilize a dividing device to form groups of articles, a separating station to cut thermoplastic packaging material to length, and a shrink tunnel to apply and shrink the material, controlled by a regulation unit to adapt to different sizes and numbers, ensuring flexible and efficient layer formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If separate processes are used to produce packages of different sizes, then manufacturing precision of package sizes is improved, but device complexity and production time increase
Solution Approach 1:
The sorting device uses a universal sorting mechanism that can handle multiple package sizes through a single process. The dividing unit with adjustable dividing rods and fingers can create different groupings (e.g., 6-pack, 12-pack, 24-pack) without requiring separate production lines, making the device multi-functional for various package configurations
Solution Approach 2:
The sorting device incorporates dynamic adjustment capabilities where the speed of dividing rods and fingers can be independently controlled relative to the conveyor belt. This dynamic control allows the same device to adapt to different package size requirements by adjusting operational parameters rather than requiring separate fixed processes
2Manufacturing precision
If separate processes are used for different package sizes, then manufacturing precision is improved, but productivity decreases
Solution Approach 1:
The sorting device maintains continuous operation by processing articles in parallel rows simultaneously. Multiple groupings are formed in one continuous pass through the sorting zone, eliminating the need to stop and reconfigure for different package sizes, thus maintaining high productivity while achieving precise package formation
Solution Approach 2:
The article stream is divided into multiple parallel rows that are sorted simultaneously. This segmentation allows the system to handle multiple package configurations in parallel, increasing overall throughput while maintaining the precision of each individual package grouping
3Ease of manufacture
If fixed-size containers are used, then ease of manufacture is improved, but adaptability decreases
Solution Approach 1:
The sorting device allows dynamic adjustment of package sizes by controlling the speed and position of dividing rods and fingers. The system can switch between different package configurations (6-pack, 12-pack, 24-pack) by adjusting operational parameters rather than requiring physical reconfiguration, maintaining ease of manufacture while achieving high adaptability
Solution Approach 2:
The system achieves different package sizes by changing operational parameters (speed ratios between conveyor belt and dividing rods, positioning of dividing fingers) rather than changing the physical container structure. This allows the same manufacturing process to produce varied package sizes simply by adjusting control parameters
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 the formation of layers with different bundle sizes and numbers, optimizing pallet space usage by dynamically adjusting the packaging material application and cutting process, thereby improving production efficiency and flexibility.
Implementation Method 1
the thermoplastic packaging material is shrunk onto each group, thus combining the items or beverage containers into a single packaging unit
Data Source
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AI summary
The invention relates to a device (1) for grouping and combining articles (5) into packages with different package sizes. The device comprises a dividing unit (3), by means of which groups (6a, 6b, 6c) can be formed from moved articles (5). Also provided is a cutting station (18) for cutting to length flat thermoplastic packaging material (20) from a material supply, a workstation (40) for applying the cut-to-length flat thermoplastic packaging material (20) to the groups (6a, 6b, 6c) of articles, and a shrinking tunnel (50), to which the groups (6a, 6b, 6c) can be fed, together with their respective applied and cut-to-length thermoplastic packaging materials (20), in order to produce the packages. The dividing unit (3) and the cutting station (18) are operatively connected to one another by an open-loop and/or closed-loop control unit (S), which has information relating to a layer to be produced from the packages. It is further provided that a) the dividing unit (3) can be actuated in a determined sequence via the open-loop and/or closed-loop control unit (S) taking into account the information for the forming of groups (6a, 6b, 6c) with different sizes, and that b) the cutting station (18) can be actuated corresponding to the determined sequence via the open-loop and/or closed-loop control unit (S) in order to cut to length the flat thermoplastic packaging material (20) with dimensions matching the size of the respective group (6a, 6b, 6c).