Modular Workpiece Carrier for Multi-Format Tray Packaging
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Solution Overview
Problem
Existing workpiece carriers for tray-shaped product packaging require separate designs for each format, leading to high production costs due to format dependency.
Innovation Solution
A base carrier with a detachable insert element that can accommodate different formats, allowing the base carrier to remain unchanged while the insert element is adapted, along with a handling device featuring independent slides and a lifting mechanism for tray-shaped product packaging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a separate workpiece carrier is used for each format, then the packaging can be handled efficiently for that specific format, but the production cost increases significantly
Solution Approach 1:
The workpiece carrier is divided into two functional segments: a universal base carrier and format-specific insert elements. The base carrier provides common structural functions (supporting trays, guiding movement), while insert elements provide format-specific features (recesses, positioning). This segmentation allows the expensive base carrier to be manufactured once and reused, while only the inexpensive insert elements need to be produced for each format, resolving the contradiction between handling efficiency and production cost.
Solution Approach 2:
The base carrier is designed with universal functionality to accommodate multiple packaging formats through detachable insert elements. The base carrier's structural features (passage openings, web structures) are designed to be format-independent, allowing it to serve multiple purposes across different product types. This multi-functionality eliminates the need to manufacture separate carriers for each format, significantly reducing production costs while maintaining handling efficiency.
2Ease of operation
If the passage opening is made large to accommodate trays, then tray insertion is easier, but the structural stability of the base carrier decreases
Solution Approach 1:
The base carrier employs local quality differentiation through its web structure. The circumferential web provides localized structural reinforcement around the passage opening, while the passage opening itself remains large for easy tray insertion. This local reinforcement strategy allows the opening to be large without compromising overall structural stability, as the web compensates for the weakened area.
Solution Approach 2:
The base carrier utilizes composite construction combining rigid materials with strategic reinforcement elements. The circumferential web acts as a reinforcement component that complements the main body material, creating a composite structure that can accommodate large passage openings while maintaining necessary structural integrity and stability.
3Adaptability or versatility
If the insert element is made detachable to enable format changes, then adaptability increases, but the device complexity increases
Solution Approach 1:
The detachable insert element system segments the carrier into a permanent base carrier and removable insert components. This segmentation enables format adaptability through simple insertion and removal operations, while keeping the overall structure relatively simple. The base carrier remains a single complex component, while inserts are simple format-specific elements, avoiding the complexity of entirely detachable carriers.
Solution Approach 2:
The insert element acts as an intermediary component between the universal base carrier and the specific packaging format requirements. Rather than making the entire carrier detachable or complex, the insert serves as a simple mediator that interfaces the base carrier with format-specific needs through straightforward attachment mechanisms, maintaining simplicity while enabling adaptability.
Data Source
AI summary
A workpiece carrier for moving at least one tray-shaped product packaging and a covering element thereof comprises a base carrier which has a passage opening in a central region for the at least one tray-shaped product packaging. An insert element, which has at least one recess for receiving the at least one tray-shaped product packaging in a suspended manner, is detachably applied onto the base carrier. The recess of the applied insert element is arranged above the passage opening of the base carrier.