Horizontal Container Stacking via Rotating Screw Mechanism
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Solution Overview
Problem
Vertical stacking systems for objects like containers or cups can be destabilizing, leading to tipping or falling during conveyance and packaging, limiting the vertical height and number of objects in a stack.
Innovation Solution
A system that rotates and nests objects from a vertical to a horizontal orientation using an infeed screw set and an orienting screw set, allowing containers to be progressively rotated and nested into each other, with a grouping mechanism to form stable horizontal stacks, minimizing instability and enabling high-speed throughput.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If vertical stacking is used, then the stacking mechanism can process containers in a traditional orientation, but the stack becomes unstable and containers may tip or fall during conveyance and packaging
Solution Approach 1:
The patent transitions the stacking orientation from vertical to horizontal by rotating containers 90 degrees during the stacking process. This dimensional change fundamentally resolves the stability issue while maintaining high throughput capability, as horizontal stacks are inherently more stable during conveyance and packaging operations
2Stability of the object's composition
If vertical stacking with limited height is used, then stack stability is maintained, but the number of containers per stack is restricted
Solution Approach 1:
By changing from vertical to horizontal stacking orientation, the system can accommodate more containers in each stack without compromising stability. The horizontal configuration allows containers to be nested side-by-side rather than stacked vertically, increasing the quantity per stack while maintaining stability throughout the packaging process
3Device complexity
If vertical stacking is used, then the stacking mechanism structure is simple, but disruption of stacking operation occurs due to tipping or falling
Solution Approach 1:
The horizontal stacking approach inherently prevents tipping and falling issues that plague vertical stacks, dramatically improving reliability. The rotational mechanism that reorients containers to horizontal position is a straightforward mechanical addition that does not significantly complicate the overall system while providing robust operational reliability
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 system achieves greater stability and higher throughput by maintaining continuous supportive contact, allowing for efficient transfer and packaging of horizontal stacks, with throughput rates ranging from 150 to 800 containers per minute.
Implementation Method 1
The orienting screw set in the first orienting portion receives the container from the infeed screw set and rotates the container from the vertical orientation to a horizontal orientation as the container is progressed axially through the orienting portion of the orienting screw set
Implementation Method 2
The orienting screw set includes first and second screws each having a first orienting portion and a second nesting portion
Implementation Method 3
The orienting screw set in the second nesting portion axially progresses the container in the horizontal orientation through a series of nesting pockets which incrementally decrease the axial offset spacing between the respective container and the preceding container
Data Source
AI summary
A system for forming horizontally stacked groups of containers includes an infeed screw set, an orienting screw set, and a grouping mechanism. Containers are presented to the infeed screw in a vertical orientation, and are progressed from the infeed screw set to the orienting screw set via a transitioning pocket defined by overlapping pockets of the infeed and orienting screw sets. As containers are progressed through the orienting screw the containers are rotated via a series of orienting pockets to a horizontal orientation and progressed via a series of nesting pockets to form a series of horizontally nested containers. The series is discharged to a grouping mechanism which separates a predefined number of containers from the series to form a horizontally stacked group, which is outfed from the stacking system.