Flap-Folding Conveyor Module With Pivoting Upstream Section
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Solution Overview
Problem
Existing food processing lines struggle to efficiently manipulate and package food products in a shingled manner while maintaining high throughput and minimizing downtime, particularly when rotating L-boards with food products for accurate flap-folding.
Innovation Solution
A flap-folding module with a conveyor system, gas jet outlet device, and edge catch device that pivots to accommodate upstream rotation modules, ensuring reliable flap-folding at high speeds, and a pitch adjustment conveyor to reduce product spacing for efficient packaging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the upstream conveyor section is fixed in position, then the structure is simple and stable, but the flap-folding module cannot be located immediately adjacent to the rotation module without causing product shifting or requiring vertical motion of the product support surface
Solution Approach 1:
The upstream conveyor section is made pivotable relative to the mid-conveyor section about a pivot axis, allowing it to dynamically adjust its position. This enables the conveyor system to adapt to the presence of the rotation module while maintaining a compact configuration, resolving the contradiction between structural simplicity and positioning flexibility.
2Productivity
If the flap-folding module is located closer to the rotation module to increase throughput, then productivity improves, but the product support surface may contact the conveyor system causing disturbance and handling errors
Solution Approach 1:
The pivotable upstream conveyor section allows the module to be positioned closer to the rotation module for increased productivity while the pivot mechanism ensures that the conveyor does not interfere with the product support surface during rotation operations, maintaining reliability.
Solution Approach 2:
The pivot axis extends transversely across the product flow path, introducing a vertical dimension to the conveyor's position adjustment. This allows the upstream conveyor section to be moved out of the rotation path without affecting the horizontal positioning of the product support surface, enabling closer module placement without interference.
3Object-affected harmful factors
If vertical motion is applied to the product support surface to avoid contacting the conveyor system, then interference is prevented, but the products on the support surface may shift out of position causing handling errors
Solution Approach 1:
Instead of vertically moving the product support surface, the upstream conveyor section is made pivotable to adjust its own position. This dynamic adjustment of the conveyor's orientation allows it to be moved out of the rotation path without requiring vertical motion of the product support surface, thereby preventing both interference and product shifting.
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 high-speed, reliable flap-folding and packaging of food products without product shifting, reducing downtime and optimizing packaging efficiency.
Implementation Method 1
a gas jet outlet device to provide an upward pulse of gas to raise a leading edge of the sheet as it passes over the gas jet outlet device
Data Source
AI summary
A flap-folding module for a food processing line is arranged to receive a food product lying on a sheet of material and to fold a portion of the sheet over the food product. A conveyor system carries the food product and sheet along a product flow path through the module. A gas jet outlet device provides a pulse of gas to raise a leading edge of the sheet, and an edge catch device receives the leading edge, temporarily retaining the leading edge whilst the food product passes beneath, thereby folding a leading portion of the sheet over at least part of the food product. The conveyor system comprises a mid-conveyor section and an upstream conveyor section which is upstream of the mid-conveyor section.