Multi-Belt Alignment Table for Bottle Queue Formation
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Solution Overview
Problem
Existing systems fail to effectively align bottles in a single file due to increasing speeds causing misalignment, leading to incidents and potential damage, despite attempts to extend alignment time and length.
Innovation Solution
A multi-belt alignment table with a guide angled above, gradually increasing speeds, and alternating tightening and spreading operations on downstream belts to facilitate bottle integration into a line, ensuring proper positioning and alignment without risk of damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the speed of bottles is increased on the alignment table, then the flow rate matches the production unit, but the alignment of bottles deteriorates
Solution Approach 1:
The alignment table is divided into multiple independent belt zones (first plurality and second plurality) that can operate at different speeds. This segmentation allows the upstream zones to accelerate bottles for flow rate matching while downstream zones maintain controlled speeds for precision alignment, resolving the contradiction between productivity and alignment precision.
Solution Approach 2:
The belt speeds are made dynamically adjustable across different zones of the alignment table. The system transitions from static uniform speed to dynamic variable speed profiles, where upstream belts operate at higher speeds to increase flow rate while downstream belts use lower speeds to maintain alignment precision, allowing both contradictory requirements to be satisfied simultaneously.
2Manufacturing precision
If the alignment table length is increased to improve alignment, then the alignment time increases, but the installation complexity and space requirements worsen
Solution Approach 1:
Instead of using a single long alignment table, the system segments the alignment function across multiple shorter belt zones. Each zone performs a specific alignment function at optimized speed, achieving the same total alignment precision as a much longer table but with reduced overall length and simpler installation.
Solution Approach 2:
The system changes the speed parameter across different zones of the alignment table rather than increasing the table length. By varying belt speeds from upstream (higher) to downstream (lower), the system achieves effective alignment within a compact space, avoiding the complexity of extending the installation.
3Productivity
If the speed variation between belts is increased to accelerate alignment, then the flow rate improves, but the risk of bottle damage and instability worsens
Solution Approach 1:
Different belt zones are assigned different speed qualities appropriate to their function. Upstream belts use higher speed variations to accelerate flow, while downstream belts use lower speed variations to protect bottles from damage. This local differentiation of speed characteristics allows the system to achieve high productivity without increasing overall bottle damage risk.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution ensures efficient and rational alignment of bottles in a single file, optimizing yield without risk of damage or misalignment, while maintaining a compact installation design adaptable to different bottle types and parameters.
Implementation Method 1
the resultant force generated by the guide causes the bottles to fit into each other
Implementation Method 2
The bottles pass from the dosing table to an alignment table which also consists of several juxtaposed endless belts
Data Source
Figure 1~8
AI summary
The method of the invention comprises guiding the bottles (1) in an angled direction on the alignment table (13) between the inlet and the outlet thereof and simultaneously gradually accelerating the speed of said bottles (1) on a portion of said table (13) from said inlet in order to reach a speed higher than the nominal speed Vn. The method further comprises submitting the bottles (1) to at least two alternating closing-up and spacing operations in the downstream portion of the alignment table (13) before the discharge thereof in the form of a queue made by a transfer conveyor (14). The equipment for implementing the method particularly comprises: a group of bands including at least two pairs of bands (15.1, 15.2, and 15.3, 15.4....) operated within each pair at different speeds in order to carry out in an alternating manner from one pair to the other closing-up and spacing operations of the bottles (1) running on said bands (15as).