Packaging Machine Conveyor Speed Segmentation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing packaging machines face limitations in increasing packaging speed due to instability and jamming issues, which reduce the usable space for carton insertion and lead to reduced package size and machine downtime.
Innovation Solution
The use of multiple conveyor belts with strategically positioned rubber-coated rollers and varying linear speeds allows for the partial overlap of packaging cartons, increasing the usable space for insertion and maintaining stability at higher speeds, thereby enhancing packaging efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the linear advancement speed of product groups and cartons is increased to raise packaging speed, then productivity improves, but stability deteriorates causing overturning of product groups
Solution Approach 1:
The single conveyor belt system is segmented into three separate conveyor belts (first, second, and third conveyor belts) operating at different speeds. This segmentation allows each belt to be optimized for its specific function: the first belt transports product groups at controlled speed, the second belt supplies cartons at a different speed, and the third belt receives packaged products. This resolves the contradiction by decoupling the speed requirements of different components.
Solution Approach 2:
The patent implements dynamic speed control where the first, second, and third conveyor belts operate at different linear speeds that can be independently adjusted. The coupling station dynamically synchronizes the arrival of product groups and cartons despite different belt speeds, allowing the system to maintain high productivity while ensuring stable packaging through controlled speed variations.
2Productivity
If the pitch between product groups is reduced to increase packaging speed, then productivity improves, but the usable space for carton insertion deteriorates
Solution Approach 1:
The packaging process is segmented into separate zones handled by different conveyor belts. The first conveyor belt handles product group transport with reduced pitch, while the second and third conveyor belts handle carton supply and receipt. This spatial segmentation allows tight spacing of product groups without compromising carton insertion space, as cartons are supplied from a separate belt system.
3Productivity
If the carton introduction speed is increased to match higher packaging speeds, then productivity improves, but control deteriorates causing sail effect and uncontrolled carton movement
Solution Approach 1:
The patent implements dynamic speed control where the second conveyor belt (supplying cartons) operates at a different linear speed than the first and third belts. This allows the carton supply speed to be independently optimized - fast enough to maintain high productivity but controlled enough to prevent sail effect. The coupling station dynamically synchronizes the different belt speeds to ensure reliable carton introduction.
4Device complexity
If a single conveyor belt is used for carton transport, then device complexity is reduced, but reliability deteriorates due to continuous jamming
Solution Approach 1:
The single conveyor belt is segmented into three separate conveyor belts (first, second, and third belts) that can operate independently. This segmentation prevents jamming from propagating throughout the entire system - if one belt experiences an issue, the others can continue operating. The coupling station coordinates between belts to maintain continuous packaging operation, significantly improving reliability.
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
This solution enables faster and safer packaging of multiple product groups by overcoming the physical and technological limitations of prior machines, reducing the risk of carton instability and jamming, and allowing for increased packaging speed without compromising package size.
Implementation Method 1
two rubber-coated rollers (40) arranged between the second conveyor belt (20) and the third conveyor belt (30). The two rollers (40) engage a front portion of each unfolded packaging carton (300) transported by said second conveyor belt (20)
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
A packaging machine (100) comprising a first conveyor belt (10), wherein said first conveyor belt (10) carries a multiplicity of groups of products (200) arranged at a first pitch (210) of distance from each other at a first speed (v1), a second conveyor belt (20) which carries a multiplicity of spread out packaging sheets (300) at a second linear speed (v2), wherein said multiplicity of spread out packaging sheets (300) are arranged at a second pitch (310) of distance from each other, a third conveyor belt (30) being arranged in succession to the second conveyor belt (20), at least one roller (40) arranged between the second conveyor belt (20) and the third conveyor belt (30), wherein said at least one roller (40) engages a front portion of each spread out packaging sheet (300) carried by said second conveyor belt (20) turning it into a spread out packaging sheet engaged (304) with said at least one roller (40), wherein said at least one roller (40) rotates at such an angular speed so as to let each engaged spread out packaging sheet (304) pass from said second linear speed (v2) to a fourth linear speed (v4), wherein said fourth linear speed (v4) of the engaged packaging sheet (304) is higher than the second linear speed (v2) of the packaging sheet (300) carried by the second conveyor belt (20), wherein each engaged spread out sheet (304) is carried at the fourth linear speed (v4) by said at least one roller (40) until a rear portion of the engaged spread out packaging sheet (304) disengages from said at least one roller (40) becoming a disengaged spread out packaging sheet (303) , wherein each spread out packaging sheet (303) is carried by said third conveyor belt (30) at a third linear speed (v3), wherein at least a front portion of the engaged packaging sheet (304) overlaps at least a rear portion of the previous disengaged packaging sheet (303), a coupling station (110) in which said disengaged spread out packaging sheet (303) carried by said third conveyor belt (30) is coupled with said group of products (200) forming a package of packaged products (201) . (Figure 2) .