Feeder System for Handling Large Flat Carton Stacks
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Solution Overview
Problem
Conventional feeder systems in the processing industry are unable to handle large units of flat carton elements due to height constraints, requiring expensive robotic arms or manual cranes, which are cumbersome and inefficient for handling heavy stacks.
Innovation Solution
A feeder system with a transport device and downholder element that clamps the edge portion of a stack, allowing it to be moved from a receiving position to a processing device, utilizing a second supporting platform and a carrier element for smooth transfer, and a portioning system that separates stacks into manageable portions using a lifting and pushing platform.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional feeder systems are used, then they can handle standard sized units, but they cannot handle large units of flat carton elements due to height constraints
Solution Approach 1:
The large unit of carton elements is divided into multiple stacks, each stack being a manageable portion that can be handled by the feeder system. The portioning system separates the large unit into individual stacks that fit within the height constraints of the feeder mechanism.
Solution Approach 2:
Instead of attempting to feed the entire large unit vertically (which exceeds height constraints), the system processes stacks horizontally by separating them along the vertical dimension first, then feeding them sequentially through the horizontal feeding mechanism.
2Ease of manufacture
If expensive robot arms or manual cranes are used to commission large units into stacks, then the stacking can be performed, but the equipment costs increase and handling becomes cumbersome
Solution Approach 1:
The portioning system is designed to automatically separate large units into stacks without requiring external robotic arms or manual crane operations. The system uses its own integrated lifting and pushing platforms to perform the commissioning operation.
Solution Approach 2:
The feeder system incorporates multiple functions including portioning, lifting, pushing, and feeding within a single integrated mechanism, eliminating the need for separate expensive equipment like robot arms or cranes.
3Quantity of substance
If multiple carton elements are stacked together, then the desired amount of cartons is achieved, but the weight of the stack becomes large and difficult to handle
Solution Approach 1:
The lifting platform is designed to dynamically support and move the stack only when needed, and the downholder element is positioned to clamp and hold the stack securely during transport. The system adapts its support mechanism based on the stack's position and movement requirements.
4Ease of operation
If a transport device moves the stack from receiving position to hand over position, then the stack can be transferred to the processing device, but the stack must be securely clamped to prevent movement
Solution Approach 1:
The downholder element is positioned in advance to clamp the stack before the transport device begins moving it. This preliminary clamping action ensures the stack is securely held from the start of the transfer operation, preventing any movement or instability during transport.
Data Source
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AI summary
The present invention relates to a feeder system for feeding a stack (101) of stackable carton elements to a processing device. The feeder system comprises a delivery ramp (103) which comprises a receiving surface (104) onto which an edge portion (111) and a centre portion (116) of the stack (101) is arrangeable. Furthermore, the feeder system comprises a transport device (125) comprising a supporting platform onto which at least a further edge portion (115) of the stack (101) is supportable, wherein the supporting platform is arranged adjacent to the receiving surface (104) such that the further edge portion (115) of the stack (101) is receivable. Furthermore, the feeder system comprises a downholder element (117), wherein the downholder element (117) is arranged for adjusting a size of a gap (705) between the downholder element (117) itself and the supporting platform, such that the further edge portion ( 115) of the stack (101) is clampable between the downholder element (117) and the supporting platform. The transport device (125) is configured to be movable between the receiving position, at which the stack (101) is receivable by the delivery ramp (103), and a hand over position at the processing device such that the stack (101) is movable from the receiving position to the hand over position.