Modular Packaging Machine With Interchangeable Head Units
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Solution Overview
Problem
Current packaging machines are limited in their ability to efficiently process multiple carton formats and rapidly adapt to different loading methods, and they struggle to reorganize the output stream of primary product containers for optimal placement into various carton formats, which hinders the production of multi-packs for shipping and distribution.
Innovation Solution
A packaging machine with a modular design featuring a carton hopper, feeder mechanisms, transfer mechanisms, and an article pick and place robot that can rearrange the input stream of articles into multiple lanes, coupled with interchangeable head units to handle different carton types, allowing for continuous formation of packages using carton blanks and articles on moving conveyors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a packaging machine is designed to process multiple carton formats and rapidly adapt to different loading methods, then adaptability and versatility are improved, but device complexity increases
Solution Approach 1:
The packaging machine is divided into separate functional modules: a first packaging subsystem for primary cartons, a second packaging subsystem for secondary cartons, and a transfer mechanism. This segmentation allows each module to be optimized for specific carton formats while maintaining overall system versatility without excessive complexity.
Solution Approach 2:
The machine incorporates interchangeable head units that can be changed to handle different carton types and formats. The transfer mechanism is designed to work with multiple packaging subsystems, enabling a single machine to perform multiple packaging functions by simply changing the head units.
2Adaptability or versatility
If the packaging machine rapidly changes format or layout to adapt to carton format requirements, then adaptability is improved, but loss of time increases
Solution Approach 1:
The machine features dynamically changeable head units that can be quickly swapped between different packaging subsystems. This dynamic configuration allows the machine to adapt to different carton formats without requiring complete layout changes, reducing reconfiguration time.
Solution Approach 2:
Head units are pre-configured for specific carton formats and can be changed in advance before production runs. This preliminary preparation eliminates the need for time-consuming on-the-fly reconfigurations during operation.
3Productivity
If the packaging machine reorganizes the output stream of primary product containers to facilitate placement into cartons, then productivity is improved, but device complexity increases
Solution Approach 1:
A transfer mechanism acts as an intermediary between the primary packaging subsystem and the secondary packaging subsystem. This intermediate component reorganizes the stream of primary product containers, facilitating efficient placement into secondary cartons while maintaining continuous operation.
Solution Approach 2:
The machine combines multiple packaging operations into a single integrated system where primary and secondary packaging occur in sequence without interruption. The transfer mechanism merges the output of one subsystem with the input requirements of another, improving overall productivity.
Data Source
AI summary
A packaging machine (10) comprising two or more packaging subsystems each capable of packaging articles (A) into a carton, wherein the packaging subsystems share a common source of articles (11) to be packaged and at least one transfer mechanism 5 (22) is provided for transferring articles (A) from the common source to any of the two or more packaging subsystems.