Linear Motor Box Insertion Apparatus with Hinged Synchronization
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Solution Overview
Problem
Existing apparatus for inserting articles, such as blister packs, into boxes are cumbersome due to complex cam mechanisms with many components, making them difficult to regulate and voluminous.
Innovation Solution
The apparatus employs a frame with hinged members and linear motors to move a thrust plate and abutting blade in alternating motion, allowing synchronized operation with conveyors to facilitate the insertion of articles into boxes, minimizing mechanical inertia and energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If cam mechanisms are used to activate the thrust plate and abutting blade, then the insertion function is achieved, but the device complexity increases due to large number of components and complicated regulation
Solution Approach 1:
The patent replaces traditional cam mechanisms with a robotic arm system comprising a robotic manipulator and a gripper. This substitution eliminates the complex cam components while achieving the same insertion function through programmable robotic motion, thereby reducing device complexity while maintaining reliability
Solution Approach 2:
The robotic arm system is self-regulating through programmable control, eliminating the need for manual regulation of complex cam mechanisms. The system automatically positions and activates the thrust plate and abutting blade according to pre-programmed sequences, reducing operational complexity
2Volume of moving object
If cam mechanisms are used to activate the thrust plate and abutting blade, then the insertion function is achieved, but the device volume increases due to voluminous components
Solution Approach 1:
The patent replaces voluminous cam mechanisms with a compact robotic arm system. The robotic manipulator and gripper occupy significantly less space while performing the same insertion function, thereby reducing the overall apparatus volume while maintaining functional reliability
Solution Approach 2:
The robotic arm system is multi-functional and can perform multiple operations (positioning, pushing, supporting) with a single integrated mechanism, eliminating the need for separate voluminous cam mechanisms for each function, thereby reducing overall device volume
3Use of energy by moving object
If linear motors are used to move the thrust plate and abutting blade, then the energy consumption is reduced, but the device complexity increases due to additional motor components
Solution Approach 1:
The patent replaces energy-inefficient cam mechanisms with linear motors that directly drive the thrust plate and abutting blade. Linear motors convert electrical energy to mechanical motion with high efficiency and no mechanical transmission losses, reducing energy consumption despite adding motor components
Solution Approach 2:
The patent changes the activation method from mechanical cam-driven motion to electrically-controlled linear motor motion. This parameter change enables precise control of the thrust plate and abutting blade movement, optimizing energy consumption through controlled activation sequences
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
This design simplifies the mechanism, reduces energy demand, and enables efficient insertion of articles by using linear motors to move the thrust plate and abutting blade in a horizontal and perpendicular direction, ensuring accurate and rapid insertion while preventing articles from arching.
Implementation Method 1
a first linear motor which is borne by the first member; a first rod which bears the first thrust plate and which is moved by the first linear motor in order to move the first thrust plate in alternating motion in a horizontal and perpendicular direction to the advancement direction
Implementation Method 2
a third member which is hinged to the frame at a first hinge axis; a fourth member which is hinged to the third member at a second hinge axis and which is hinged to the second member at a third hinge axis
Data Source
Figure 1~2
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AI summary
An apparatus for inserting articles (3) internally of boxes (7), which apparatus (1): comprises a first thrust plate (9) for pushing at least an article internally of a box (7); comprises a first abutting blade (36) for at least partially entering the box (7) and providing an upper abutment for facilitating insertion of the article (3) in the box (7); a first straight guide (10) solidly constrained to the frame (8), which straight guide is parallel to the advancement direction; a first member (11) which can slide along the first straight guide (10) and which is provided with a second straight guide (12) that is vertical and perpendicular to the advancement direction; a first linear motor (13) which is borne by the first member (11); a first rod (14) which bears the first thrust plate (9) and which is moved by the first linear motor (13) in order to move the first thrust plate (9) in alternating motion in a horizontal and perpendicular direction to the advancement direction; a second member (15) which can slide along the second straight guide (12); a second linear motor (16) which is borne by the second member (15); a second rod (17) which bears the first abutting blade (34) and which is moved by the second linear motor (16) such as to move in alternating motion in a horizontal and perpendicular direction to the advancement direction; a third member (18) which is hinged to the frame (8); a fourth member (20) which is hinged to the third member (18) and to the second member (15); a fifth member (23) which is hinged to the frame (8); a sixth member (24) which is hinged to the fifth member (23) at a fourth hinge axis (25) and which is hinged to the first member (11); the third member (18) and the fifth member (23) being activatable in rotation such as to move the first member (11) and the second member (15) in synchrony with the first conveyor (2) and with the second conveyor (6) and in order to enable movement of the first thrust plate (9) and the first abutting blade (34) by action respectively of the first linear motor (13) and the second linear motor (16) in order to insert at least an article internally of a box (7).