Napkin Pack Dispatching Arrangement for Bulk and Small Mode Switching
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Solution Overview
Problem
Existing machinery is incapable of producing both bulk and small packs of napkins on a single processing line, with prior methods and apparatuses either limited to bulk packs or small packs, requiring separate setups and processes.
Innovation Solution
A pack dispatching arrangement that can alternate between bulk and small pack modes, using a single separator to orient packs on edges or faces, allowing for efficient transfer to respective transfer stations and wrapping, facilitated by a control system and pack turning mechanisms like pivotable or rotatable arms and air nozzles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single processing line is used to produce both bulk packs and small packs, then production efficiency is improved and equipment cost is reduced, but the complexity of the dispatching system increases
Solution Approach 1:
The pack dispatching arrangement is designed to perform multiple functions by alternatively dispatching both bulk packs and small packs through the same processing line. The system includes a bulk pack mode for delivering bulk packs to a bulk pack transfer station and a small pack mode for delivering small packs to a small pack transfer station, allowing one piece of equipment to replace what would traditionally require separate production lines for each pack type.
Solution Approach 2:
The dispatching system incorporates dynamic elements including a rotatable pack turner that can rotate to different positions to accommodate different pack types, and a pivotable arm that can pivot between positions to direct packs to different transfer stations. These dynamic components enable the system to adapt its configuration based on whether bulk packs or small packs are being processed.
2Adaptability or versatility
If separate machinery is used for bulk packs and small packs, then operational simplicity is maintained, but equipment cost and production flexibility are reduced
Solution Approach 1:
The separator arrangement and pack dispatching arrangement work together as a universal system that can process both bulk packs and small packs on a single processing line. The control system enables the apparatus to alternatively produce either bulk packs or small packs, providing production flexibility without requiring separate dedicated machinery for each pack type.
3Ease of manufacture
If packs are oriented on edges throughout the process, then bulk pack production is simplified, but small pack production requires additional orientation changes
Solution Approach 1:
The pack turner is designed with rotational capability to change pack orientation dynamically. In bulk pack mode, the pack turner can be positioned to maintain edge orientation, while in small pack mode, it rotates to orient packs on their faces. The pivotable arm also dynamically adjusts its position and angle to accommodate the different orientation requirements of bulk packs versus small packs.
Solution Approach 2:
The pack turner acts as an intermediary device between the separator arrangement and the transfer stations. It receives packs in a uniform orientation from the separator and then modifies their orientation as needed before delivering them to the appropriate transfer station, whether that be edge-oriented for bulk packs or face-oriented for small packs.
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
Enables the production of either bulk or small packs on a single processing line, optimizing production efficiency by utilizing a single separator and dispatching system, reducing the need for multiple machines and processes.
Implementation Method 1
at least one air nozzle configured for directing a stream of air against the upstream face of the small pack to urge the small pack into the receptacle... An air nozzle is operatively connected and configured for directing a jet of air against the upstream face of the small pack for urging the small pack into the receptacle
Data Source
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Figure 7
AI summary
An apparatus and method are provided, for alternatively producing either small or bulk packs of napkins from a stack of folded napkins produced by one folding machine, through use of a pack dispatching arrangement (1000) having an inlet (1002), a small pack transfer station (1006) and a bulk pack transfer station (1004), and configured for operation in a small pack mode for dispatching a stream of spaced apart small packs (PS) of folded sheets separated from the stack of folded sheets, and received at an inlet (1002) of the pack dispatching arrangement (1000), to the small pack transfer station (1006), and alternatively operable in a bulk pack mode for dispatching a stream of spaced apart bulk packs (PB) of folded sheets separated from the stack of folded sheets, and received at an inlet (1002) of the pack dispatching arrangement (1000), to the bulk pack transfer station (1004).