Multi-Row Packaging Tray Filling Synchronization
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Solution Overview
Problem
Existing multi-row packaging tray filling machines operate at low speeds due to the need for sequential filling of rows, resulting in insufficient output for modern production demands.
Innovation Solution
A method and apparatus that synchronizes and synchronously fills multiple rows of a packaging tray by dividing a single-row product stream into parallel lanes, allowing simultaneous filling of each row, with synchronized movement and positioning to achieve high-speed filling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If rows are filled sequentially one after another, then the filling process is simple to control, but the packaging speed is slow and output is low
Solution Approach 1:
The patent divides the single-row product stream into multiple parallel lanes, with each lane corresponding to one row of the packaging tray. This segmentation allows simultaneous filling of multiple rows, increasing packaging speed from 800-1000 products per minute to significantly higher throughput by eliminating sequential filling constraints
Solution Approach 2:
The patent employs dynamic synchronization mechanisms where the speed of each conveying lane is independently adjustable to match the positioning speed of the packaging tray. This dynamic speed matching ensures that products from multiple lanes arrive at their respective rows simultaneously, enabling high-speed parallel filling while maintaining precise positioning accuracy
2Productivity
If feeding devices move back and forth multiple times to fill each row, then the mechanism is simple, but the filling time increases and efficiency decreases
Solution Approach 1:
The patent implements continuous parallel conveying on multiple lanes simultaneously, eliminating the back-and-forth movement of feeding devices. All lanes operate continuously and synchronously, with products being transferred to the packaging tray in parallel, thereby minimizing idle time and maximizing the continuous useful action of the filling process
Solution Approach 2:
The patent transitions from one-dimensional sequential filling (one row at a time) to multi-dimensional parallel filling by introducing multiple conveying lanes operating simultaneously. This dimensional expansion allows products to be distributed across multiple rows at the same time, dramatically reducing total filling time and increasing output capacity
Data Source
AI summary
A tray loading packaging machine that carries out a method for filling a multi-row packaging tray with piece-form products at a high performance level, having the following steps: dividing up a single-row stream of piece-form products onto a plurality of lanes arranged substantially parallel to one another in order to convey the products further; synchronizing the individual streams of products on the plurality or lanes with one another such that in each case one product from one lane can be transferred to the packaging tray substantially at the same time as in each case one product from the other lanes; and transferring the produces to the packaging tray, wherein in each case one product from one lane is transferred to one row of the packaging tray.