Feeder Module Dented Chain for Scratch-Free Blank Discharge
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Solution Overview
Problem
Existing feeder modules in converting machines face challenges in maintaining consistent contact pressure between the discharge conveyor and blanks, leading to deformation marks due to varying stack weight and height, which is exacerbated by the need for precise alignment and discharge of individual sheets or blanks.
Innovation Solution
A feeder module design featuring an upper feeder assembly with a dented chain and gauges that support the upper portion of the stack, ensuring consistent friction and calibrated contact pressure through a dented chain with teeth that engage between blanks, maintaining the stack's weight constant and preventing scratching.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the discharge conveyor applies sufficient pressure to the blanks to ensure correct contact and discharge, then the discharge reliability is improved, but deformation marks and scratching occur on the blanks
Solution Approach 1:
The feeding mechanism is divided into two separate components: a discharge conveyor that applies downward pressure and a dented chain with teeth that provides upward support. This segmentation allows each component to perform its specific function independently, with the teeth supporting the blank weight and the conveyor applying controlled pressure without causing deformation.
Solution Approach 2:
The dented chain with teeth acts as an intermediary element between the blank stack and the discharge conveyor. The teeth engage with the blanks to provide upward support, mediating the interaction between the conveyor's downward pressure and the blanks, thereby preventing direct contact that would cause deformation marks.
2Stability of the object's composition
If the discharge conveyor pressure is increased to maintain consistent contact, then the contact pressure consistency is improved, but the risk of scratching and deformation increases
Solution Approach 1:
The dented chain with teeth provides an upward supporting force that counteracts the downward gravitational force on the blank stack. This counterweight mechanism maintains consistent contact pressure by balancing the forces, allowing the discharge conveyor to apply steady pressure without causing scratching or deformation.
3Adaptability or versatility
If the stack weight varies during production, then the adaptability to different production conditions is improved, but the contact pressure between discharge conveyor and blanks becomes inconsistent
Solution Approach 1:
The dented chain with teeth provides a dynamic support system that automatically adapts to varying stack weights. The teeth engage with the blanks to provide upward support proportional to the stack weight, while the discharge conveyor maintains consistent downward pressure. This dynamic balance ensures stable contact pressure regardless of stack weight variations during production.
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
The solution ensures precise alignment and discharge of blanks without deformation, maintaining consistent contact pressure and reducing the risk of scratching, while accommodating varying stack weights and heights.
Implementation Method 1
the friction may be maintained constant and calibrated to avoid scratching the blanks
Implementation Method 2
The lower feeder assembly comprises a loading surface configured to receive a stack of blanks, and a discharge conveyor configured to grasp a lowermost positioned blank in the stack and convey it forward
Implementation Method 3
The upper feeder assembly comprises at least one gauge configured to abut against a front side of the stack
Data Source
Figure 1
Figure 2a~2b
Figure 3
AI summary
The present invention relates to a feeder module (10) comprising a loading surface (26) configured to receive a stack (S) of blanks(2). The feeder module (10) comprising an upper feeder assembly (22) and a lower feeder assembly (24). The upper feeder assembly (22) comprises a dented chain (44) provided with a plurality of teeth (52), and wherein the teeth (52) are configured to enter into the stack (S) in-between the blanks (2).