Modular Slat Exchange for Fast Thermo-Welding Format Changes
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing thermo-welding machines with chain conveyors require extensive manual intervention and risk operator safety due to the need to replace the entire chain conveyor for shape changes, leading to long production stops and potential machinery damage.
Innovation Solution
A slat exchange system with a removable part and hooking mechanism allows for automated slat changes using a robot, ensuring alignment and preventing misalignment through a check sensor, and facilitating quick format changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the entire chain conveyor is replaced to change alveolar shape, then the machine can accommodate different container shapes, but production stops for many hours and operators are at risk
Solution Approach 1:
The chain conveyor is divided into modular slats that can be independently replaced. Each slat is a separate component with standardized dimensions and attachment mechanisms, allowing individual slat replacement rather than replacing the entire chain conveyor. This segmentation enables quick format changes by swapping only the necessary slats while keeping the rest of the system in place.
Solution Approach 2:
The slats are designed with universal attachment mechanisms that can accommodate different alveolar shapes. The standardized mounting system allows the same slat structure to be used with various container configurations, making the chain conveyor adaptable to multiple container types without requiring complete system replacement.
2Adaptability or versatility
If the entire chain conveyor is replaced to change alveolar shape, then different container shapes can be welded, but the risk of machinery damage due to assembly errors is very high
Solution Approach 1:
The slats are pre-assembled with the correct alveolar shapes and attachment mechanisms before being installed on the chain conveyor. The standardized mounting system includes pre-positioned holes and attachment points that guide correct assembly, reducing the risk of assembly errors. Check sensors verify proper slat installation before the machine operates, preventing damage from misaligned or incorrectly installed components.
Solution Approach 2:
Check sensors are integrated into the system to detect and verify the correct positioning and installation of slats. The sensors provide feedback on slat alignment and attachment status, alerting operators to any installation errors before they can cause machinery damage. This feedback mechanism ensures reliable operation by preventing the machine from running with improperly installed components.
3Ease of manufacture
If manual intervention is used to replace the chain conveyor, then slat changes can be performed, but operator safety is at risk and many hours are required
Solution Approach 1:
The manual mechanical process of replacing entire chain conveyors is substituted with an automated system that uses robotic arms to handle and install individual slats. The automated change system mechanically manipulates the slats using programmed movements, eliminating the need for operators to manually disassemble and reassemble heavy chain conveyor components. This substitution maintains the ability to perform slat changes while dramatically improving safety and reducing time requirements.
Solution Approach 2:
The slat replacement system is designed to be self-servicing where possible, with slats that automatically align and attach to the chain conveyor through guide rails and snap-fit mechanisms. The system requires minimal manual intervention, as the slats self-position and self-secure during the replacement process, reducing operator exposure to hazardous areas and simplifying the changeover procedure.
Data Source
AI summary
A slat exchange system in thermo-welding machines having cells or alveolar cavities and similar systems, adapted to be adopted on a thermo-welding machine having cells or alveolar cavities and/or a similar system having a chain conveyor, a transmission chain, and an IT management apparatus, and being characterized in that it includes: at least one fixed slat part permanently connected to the chain conveyor; at least one removable slat part with one or more shapes adapted to be hooked and unhooked from the fixed slat part in order to be exchanged with another; at least one hooking and unhooking mechanism with a pin, a handle and a bar with spring, installed on the fixed slat part and adapted to allow hooking and unhooking the removable slat part.