Egg Carton Conveyor Switching for Automated Tray Stacking
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing stacking and conveying systems for egg cartons are inefficient for smaller farms, as they require large investments and are not cost-effective for automation.
Innovation Solution
A method and device utilizing sensors to differentiate between egg cartons and stacked trays, enabling continuous and discontinuous conveyance on the same conveyor line, with motor-driven and gravity-driven transitions, and a control system to manage stacking and conveyance efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If parallel conveyor lines are used for stacking egg cartons, then stacking automation is achieved, but system complexity and cost increase significantly
Solution Approach 1:
The system segments the conveyor operation into two distinct modes: continuous conveyance mode for individual egg cartons and discontinuous conveyance mode for stacked egg trays. This segmentation allows a single conveyor line to handle different operations sequentially, eliminating the need for multiple parallel conveyor lines while maintaining automation capability.
Solution Approach 2:
The conveyor line dynamically switches between continuous and discontinuous operation modes based on real-time detection of egg cartons versus stacked trays. The control system adjusts the conveyor's operational state dynamically, enabling one conveyor line to perform multiple functions that would traditionally require separate dedicated lines.
2Productivity
If a single conveyor line handles both egg cartons and stacked trays, then conveyor utilization increases, but differentiation and control complexity increases
Solution Approach 1:
The system replaces complex mechanical differentiation mechanisms with optical or sensor-based detection systems. Sensors automatically identify whether an object on the conveyor is an individual egg carton or a stacked tray, and the control system automatically adjusts conveyance mode accordingly, reducing mechanical complexity while improving control precision.
Solution Approach 2:
The control system continuously receives feedback from sensors detecting objects on the conveyor line and automatically adjusts the conveyance mode in real-time. This closed-loop feedback mechanism simplifies control by allowing the system to self-regulate based on detected object types, reducing the need for complex manual control logic.
3Extent of automation
If stacked trays are conveyed intermittently, then stacking is achieved, but transport time increases
Solution Approach 1:
The system maintains continuous conveyor operation by seamlessly alternating between continuous conveyance of individual cartons and discontinuous conveyance for stacking. The transition between modes is smooth and automated, ensuring that the conveyor line remains continuously productive without idle time, thereby minimizing overall transport time while maintaining full automation capability.
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
Enhances conveyor belt utilization and automates stacking for smaller businesses, improving efficiency and reducing manual intervention.
Implementation Method 1
a sensor distinguishes between egg cartons and stacked egg trays in the egg packaging
Implementation Method 2
the egg cartons, during their discontinuous transport along the conveyor, experience a temporary change from a motor-driven driving force to a gravity-driven driving force
Data Source
Figure 1
Figure 2
AI summary
In a method for stacking and conveying egg cartons filled with chicken eggs on a conveyor line, sensors distinguish between egg cartons and tray layers. Control commands are generated from these sensors to control conveyor elements located on the conveyor line such that the egg cartons are continuously conveyed along the conveyor line, and the tray layers are stacked into stacks of goods, which are then discontinuously conveyed along the conveyor line. In a device for carrying out the method, a stacking machine is arranged between two conveyor belts and is connected to the conveyor belts via a controller. The controller has a sensor arranged on one of the conveyor belts to distinguish between the egg cartons.The control system has two operating states: a first operating state in which the conveyor belts are connected to one another to form a continuous conveyor for the egg boxes, and a second operating state in which the conveyor belts are connected to one another via the stacking machine to form a discontinuous conveyor for the tray layers.