Hygiene Product Packaging Conveyor with Dynamic Machine Assignment
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Solution Overview
Problem
Existing production and packaging installations for hygiene products, such as diapers and sanitary napkins, are limited by the need for two identical packaging machines, which restricts the ability to produce varied pack sizes and can lead to a production halt if one machine fails.
Innovation Solution
A method and installation where hygiene products are individually or in groups supplied to a continuously circulating conveyor with multiple holders, allowing dynamic assignment to packaging machines, enabling variable pack sizes and automatic re-routing in case of machine failure, with a central control system adapting performance values to maintain efficient packaging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If two identical packaging machines are used in parallel, then the production capacity is increased, but the flexibility to produce different pack sizes is reduced
Solution Approach 1:
The system segments the product flow by introducing a grouping conveyor with multiple holders that can be individually assigned to different packaging machines. This allows the product stream to be divided and directed to different machines based on the desired pack size, enabling one machine to handle multiple pack configurations while maintaining high production capacity.
Solution Approach 2:
The system implements dynamic assignment where the control unit can reassign holders and product groups to different packaging machines in real-time based on production requirements. This dynamic flexibility allows the same physical infrastructure to produce variable pack sizes without requiring dedicated machines for each pack type.
2Productivity
If two identical packaging machines are used in parallel, then the production capacity is increased, but the system reliability is reduced as the entire installation stops when one machine fails
Solution Approach 1:
The system prepares for machine failure by implementing pre-configurable reassignment capabilities. The control unit is designed to automatically detect machine failures and redistribute the workload to operational machines before production is impacted, ensuring continuous operation without manual intervention.
Solution Approach 2:
The grouping conveyor and control system are designed with universal functionality to serve multiple packaging machines with different capabilities. When one machine fails, the system can universally redirect all product groups to the remaining functional machine, ensuring system reliability while maintaining the capacity to produce various pack sizes.
3Ease of manufacture
If the number of products in each holder is fixed in advance, then the packaging process is simplified, but the ability to adapt to different packaging requirements is reduced
Solution Approach 1:
The system replaces fixed holder configurations with dynamic, software-controlled assignment. The control unit can adjust the number of products per holder and their destination machine in real-time based on packaging requirements, maintaining simple physical hardware while achieving complex adaptability through intelligent control.
Solution Approach 2:
The system enables parameter changes in the packaging process by allowing the control unit to modify product group sizes and machine assignments without physical reconfiguration. This changes the operational parameters dynamically while keeping the mechanical system simple and unchanged.
Data Source
AI summary
A method for operating a production and packaging installation for hygiene products, wherein the hygiene products are produced by a production machine, and the hygiene products produced are packaged by at least two packaging machines which are assigned to the production machine and are intended for packaging the hygiene products in particular so that they are ready for dispatch. At least two packaging machines assigned to a grouping conveyor form a machine group, wherein the performance of the packaging machines of the machine group are adapted automatically in accordance with the performance of the production machine and/or the individual performances available for the packaging machines of the machine group, and/or wherein the number of hygiene products with which the holders of the grouping conveyor are filled is selected automatically for each holder in dependence on which of the packaging machines the hygiene product of the respective holder is intended.