Intelligent Conveyor System for Irregular Article Packaging
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Solution Overview
Problem
Conventional packaging systems are complex, struggle with irregularly shaped articles, and cannot easily adjust to different sizes or configurations, often resulting in article back-ups and inefficient delivery to unloading stations.
Innovation Solution
A packaging system utilizing intelligent conveyor assemblies with individually controlled electromagnet coils and movable pallets, allowing for independent control of each pallet's motion and orientation, along with a control system that can adjust delivery speed and handle articles into desired configurations of rows, columns, and stacks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional conveyor systems with conveyor belts are used to move articles, then articles can be transported from one location to another, but the system cannot automatically adjust delivery speed to different unloading stations, resulting in article back-ups and displacement
Solution Approach 1:
The conveyor system is divided into multiple independently controllable sections, each capable of adjusting its speed separately. This allows different sections to deliver articles to different unloading stations at optimized speeds, preventing back-ups while maintaining high productivity.
Solution Approach 2:
The conveyor system implements dynamic speed control where each section can adjust its operating speed in real-time based on the status of downstream unloading stations. This dynamic adaptation eliminates the rigidity of conventional fixed-speed conveyors and prevents article displacement.
2Ease of manufacture
If conventional packaging systems are designed for specific article configurations, then they can handle standardized packaging, but they cannot easily convert to handle different sizes or arrange articles into different configurations
Solution Approach 1:
The packaging system is designed with universal components that can perform multiple functions. The conveyor sections and positioning mechanisms can be reconfigured through software control to handle various article sizes and arrange them in different packaging configurations without physical modifications.
Solution Approach 2:
The system uses programmable parameters to control article positioning and packaging configuration. By changing software parameters rather than physical components, the system can easily adapt to different article sizes and packaging requirements, greatly improving reconfiguration ease.
3Productivity
If conventional conveyor systems operate with fixed speed, then they are simple to control, but they result in article back-ups when delivery speed cannot be adjusted to match unloading capacity
Solution Approach 1:
The conveyor system incorporates feedback mechanisms that monitor the status of unloading stations and automatically adjust delivery speeds. Sensors detect article accumulation or unloading capacity, and the control system responds by modifying conveyor section speeds to maintain optimal flow and prevent back-ups.
4Productivity
If manual article removal from conveyor is used, then system complexity is reduced, but productivity decreases due to reliance on individual ability and manual placement speed
Solution Approach 1:
The system uses automated mechanisms that perform the unloading and placement functions without manual intervention. The intelligent conveyor sections automatically position and deposit articles at the correct locations, enabling the system to serve itself and greatly increasing unloading speed beyond human capability.
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 efficient handling of irregularly shaped articles, easy conversion for different sizes, and automatic adjustment of delivery to prevent back-ups, ensuring articles are packed into desired configurations and delivered to unloading stations effectively.
Implementation Method 1
Each section has a plurality of individually controlled electromagnet coils effective for creating electromagnetic fields
Implementation Method 2
The reaction elements cooperate with the electromagnetic coils positioned along the interconnected sections that operate to move the pallets when the coils are energized
Data Source
AI summary
A packaging system and method for receiving articles from a first location, such as a product delivery system, transporting the articles to a second location for unloading the articles such that they are placed in a desired orientation and number of columns, rows, and stacks.