Modular Drawer Storage System for Bottling Line Hygiene
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Solution Overview
Problem
Existing bottling lines for thermoplastic containers face inefficiencies in storage system management and hygiene, leading to disruptions and suboptimal operation.
Innovation Solution
A modular storage system with drawers, a conveyor, loading and unloading bays, and a control unit that manages the movement and sanitation of containers using sensors, manipulators, and sterilizing means to ensure efficient storage and hygiene standards.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a storage system is introduced to buffer parisons and avoid interruptions, then productivity is improved, but device complexity increases due to the need for additional storage infrastructure
Solution Approach 1:
The storage system is divided into multiple compartments (e.g., 10 compartments arranged in 2 rows of 5), each capable of holding drawers independently. This segmentation allows the system to buffer larger quantities of parisons while maintaining modular architecture, reducing overall complexity through standardized repeating units.
Solution Approach 2:
Drawers are nested within compartments, and compartments are arranged within the storage system framework. The conveyor system nests its movement path within the storage structure. This nested arrangement maximizes storage capacity within a compact footprint, improving productivity without proportionally increasing device complexity.
2Loss of time
If manual or simple storage management is used, then device complexity is reduced, but loss of time increases due to inefficient object management and line interruptions
Solution Approach 1:
Sensors are installed in the storage system to detect the presence, quantity, and position of parisons in each compartment and drawer. This feedback is transmitted to the control unit, which automatically manages drawer positioning and conveyor operation. The feedback mechanism prevents line interruptions by maintaining optimal buffer levels without requiring complex manual monitoring systems.
Solution Approach 2:
The storage system is equipped with an automatic conveyor that autonomously transports drawers between compartments, loading bay, and unloading bay. The system self-regulates parison distribution using sensors and control logic, eliminating the need for manual intervention and reducing line interruption time without adding excessive complexity.
3Object-affected harmful factors
If traditional storage methods are used, then device complexity is minimized, but object-generated harmful factors increase due to poor hygiene conditions
Solution Approach 1:
The drawer extraction mechanism allows drawers containing parisons to be removed from compartments and transported to dedicated washing stations. This separation enables targeted sanitation of storage containers without disrupting the main storage function, improving hygiene while keeping the sanitation system modular and manageable in complexity.
Solution Approach 2:
Drawers are washed and sanitized before being placed into storage compartments, and can be re-washed before unloading. This preliminary sanitation action ensures high hygiene standards for stored parisons without requiring continuous complex sterilization systems throughout the entire storage volume.
4Loss of time
If automated conveyor and manipulator systems are added, then loss of time is reduced through efficient object management, but device complexity increases
Solution Approach 1:
The conveyor system serves multiple functions: transporting drawers from compartments to loading bay, moving loaded drawers to unloading bay, and relocating drawers between compartments. The manipulators perform both loading (placing parisons in drawers) and unloading (removing parisons from drawers) operations. This multi-functionality reduces the number of separate systems needed, improving efficiency without proportionally increasing complexity.
Data Source
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AI summary
A storage system for storing objects of plastic material processed in a bottling line (45) comprises: a plurality of drawers (4) configured to contain groups of objects (5); a frame (2) which defines a plurality of compartments (3) configured to house the drawers (4); a conveyor (8) movable in the storage system (1) itself and configured to access the compartments (3) in such a way as to withdraw and place drawers (4) from and into the compartments (4); a loading bay (11) having one or more loading compartments for receiving corresponding drawers (4) and having a loading manipulator (28) configured to place in the drawers (4) the loose objects (5) received from an infeed conveyor (29); an unloading bay (12) having at least one unloading compartment for receiving a corresponding drawer (4) and having an unloading manipulator (41) configured to place onto an outfeed conveyor (43, 44) the loose objects (5) stored in the drawer (4).