Package Grouping Conveyor Using Cyclic Acceleration and Deceleration
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Solution Overview
Problem
Existing units for grouping packages are complex, costly, and lack robustness at high production speeds, necessitating a simpler and more efficient solution.
Innovation Solution
A unit and method for grouping packages that utilizes a conveyor device and a gripping device to accelerate or decelerate a leading package within a group, reducing gaps between packages and creating gaps between groups, using a gripping device with movable gripping pads or a combination of belts and a guide wall to minimize inertia and maintain package alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If known units for grouping packages are used, then packages can be organized into groups, but the device complexity and cost increase
Solution Approach 1:
The conveyor belt is segmented into multiple independent zones (first conveyor zone, second conveyor zone, third conveyor zone) that can operate independently to perform different functions: transporting packages, gripping/accelerating individual packages, and creating gaps between groups. This segmentation allows the system to achieve complex grouping functionality through simple, modular zones rather than a complex monolithic structure.
Solution Approach 2:
The system uses the packages themselves as the gripping mechanism by creating friction between package surfaces. When the conveyor belt accelerates or decelerates, the friction between adjacent packages causes them to push or pull each other, automatically forming groups without requiring complex external gripping mechanisms. The packages self-organize through controlled friction-based interactions.
2Productivity
If high production speed is achieved, then productivity increases, but the robustness and reliability decrease
Solution Approach 1:
The conveyor belt operates in dynamic motion cycles, alternating between acceleration and deceleration phases. During acceleration, packages are pushed together to form groups; during deceleration, gaps are created between groups. This dynamic operation allows the system to maintain reliable package grouping even at high production speeds by continuously adapting the motion profile to the current package configuration.
Solution Approach 2:
The conveyor belt maintains continuous motion without stopping, performing all grouping operations during transit. The cyclic acceleration-deceleration pattern ensures that grouping actions are performed continuously as packages move through the different zones, eliminating idle time and maintaining high productivity while ensuring reliable grouping through repeated action cycles.
3Manufacturing precision
If multiple components are used for package manipulation, then grouping precision improves, but the number of components and cost increase
Solution Approach 1:
The single conveyor belt performs multiple functions that would traditionally require separate components: it transports packages, grips individual packages through friction, accelerates packages to close gaps, decelerates packages to create gaps between groups, and maintains package alignment. This multi-functional design achieves precise package manipulation with minimal components.
Solution Approach 2:
Friction acts as an intermediary mechanism between the conveyor belt and packages, and between adjacent packages themselves. The friction force transmitted through package contact surfaces enables precise force transfer and package-to-package interaction, achieving accurate alignment and grouping without requiring direct mechanical contact between the conveyor and each package.
4Manufacturing precision
If gaps between packages are reduced to form tight groups, then grouping quality improves, but the force required to manipulate packages increases
Solution Approach 1:
The system uses deceleration phases to counterbalance the force requirements of acceleration phases. During deceleration, packages naturally push together due to inertia, creating tight groups without requiring additional gripping force. This counterbalancing of force requirements through cyclic acceleration-deceleration patterns reduces the peak force needed compared to continuous gripping mechanisms.
Solution Approach 2:
Adjacent packages use friction between their surfaces to push and pull each other into alignment and tight grouping. When the conveyor accelerates, the friction force transmitted through package contact causes packages to push against each other, automatically forming tight groups without requiring external force application to each individual package.
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 effectively organizes packages into defined groups without gaps, reduces maintenance needs, and enhances robustness and speed, minimizing errors and costs while maintaining high production efficiency.
Implementation Method 1
a gripping device (12) arranged alongside said advancing path P and configured to cyclically grip said one package (2b) of each successive respective groups
Data Source
Figure 1
Figure 2
Figure 3A~3B
AI summary
There is described a unit (8) for grouping packages (2) containing a pourable product in groups (10), the unit (8) comprises: a conveyor device (11) for advancing a sequence of packages (2), each package (2) of the sequence of packages (2) being spaced from one another by a first gap (G1); a gripping device (12) configured to grip one package (2b) of the sequence of packages (2) at a time; the gripping device (12) is configured to: accelerate the gripped package (2b) with respect to the other packages (2) and towards preceding packages (2) so that the gripped package (2b) abuts against the immediately adjacent preceding package (2) thereby pushing a number of preceding packages (2) together for reducing or zeroing said first gap (G1) between them; and/or to decelerate the gripped package (2b) with respect to the other packages (2) and towards following packages (2) so that the gripped package (2b) is distanced from the preceding packages (2) and abuts against the immediately adjacent following package (2b) thereby pushing a number of following packages (2) together for reducing or zeroing said first gap (G1) between them.