Merge Conveyor Aligning Item Arrangements for Packaging
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Solution Overview
Problem
The existing packaging systems face challenges in increasing throughput due to the time-consuming process of arranging items of varying sizes and numbers for automated packaging, particularly in feeding them to the packaging station, which can result in items tumbling or falling due to high accelerations during transportation.
Innovation Solution
A system utilizing multiple conveyors, including a merge conveyor that aligns and transports arrangements in parallel, allowing for increased throughput by merging and aligning items to be packaged in custom-sized cardboard boxes while maintaining low acceleration and preventing items from tumbling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If items are transported on a single conveyor from arranging station to packaging station, then the system is simple, but the throughput is limited and items may tumble due to high accelerations
Solution Approach 1:
The transport system is divided into multiple independent conveyor lines (first conveyor, second conveyor, third conveyor) that operate in parallel. Each conveyor handles a separate flow of arrangements, allowing simultaneous transport of multiple items without interference, thereby increasing throughput while maintaining low acceleration on each individual conveyor.
Solution Approach 2:
The system transitions from a single linear transport path to a multi-dimensional arrangement where conveyors are positioned at different locations and angles. The merge conveyor integrates flows from multiple directions, creating a spatially distributed transport network that increases capacity without compromising stability.
2Productivity
If conveyor speed is increased to make up for arranging time, then throughput increases, but items tumble and fall from the conveyor
Solution Approach 1:
The transport task is segmented across multiple conveyors operating in parallel. Each conveyor handles a subset of arrangements at moderate speeds, ensuring stability. The combined capacity of multiple slower conveyors equals or exceeds that of a single fast conveyor, maintaining throughput while preventing item tumble.
Solution Approach 2:
Multiple conveyors operate continuously and simultaneously, each transporting arrangements without interruption. This parallel continuous operation eliminates the need to increase speed on individual conveyors to compensate for arranging time, as the system's overall throughput is the sum of all concurrent transport streams.
3Productivity
If multiple conveyors are used to increase throughput, then more arrangements can be fed to packaging station, but system complexity increases
Solution Approach 1:
The system uses multiple independent conveyor units that can be implemented using standardized components. Each conveyor is a separate, manageable module, making the overall complex system composed of simple, replaceable parts that are easier to maintain and control individually.
Solution Approach 2:
The merge conveyor combines flows from multiple independent conveyors into a single stream for the packaging station. This merging function is achieved through a straightforward geometric arrangement where conveyors are positioned to feed into a common destination, minimizing the need for complex synchronization mechanisms.
Data Source
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AI summary
System (10) for transporting items to a packaging station comprising at least a first, a second and a third conveyor, said first conveyor (12) configured for transporting arrangements (26) of one or more items in a first transport direction (16) to the third conveyor (20), said second conveyor (14) configured for transporting arrangements of one or more items in a second transport direction (18) to the third conveyor (20), said third conveyor (20) configured for transporting said arrangements from the first and the second conveyor in a third transport direction (22), a fourth and a fifth transport direction (24) towards a packaging station.