Packaging Forming Unit Synchronizing Layered Roll Transfer
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing forming units for packaging rolls in layers face issues with roll interference and limited high production rates due to elevator movement between layers, making them inefficient and costly for handling and transportation.
Innovation Solution
A packaging machine unit with three parallel feed surfaces and a synchronized conveyor system, utilizing an elevator and containment walls to align and compress rolls, ensuring simultaneous transfer and release of layers to form stable stacks, thereby increasing production rates and reducing maintenance costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If rolls are stacked in layers on an elevator by transferring them one layer at a time, then the packs are easy to handle and transport, but the production rate is limited due to elevator movement between layers
Solution Approach 1:
The forming unit is divided into multiple independent feed surfaces (first, second, third feed surfaces) that operate in parallel, each capable of feeding rolls independently. This segmentation allows simultaneous feeding of multiple layers without requiring sequential elevator movements, thereby increasing production rate while maintaining the layered stacking capability for easy handling and transport.
Solution Approach 2:
The invention transitions from a single-vertical-elevator approach to a multi-level horizontal feed surface configuration. By arranging feed surfaces at different heights and positions, the system enables simultaneous multi-layer feeding in a three-dimensional space, eliminating the bottleneck of sequential elevator movements and significantly boosting production rate.
2Productivity
If rolls are placed one layer on top of another on the elevator, then layered packs are formed, but interference between rolls occurs due to sliding relative to one another
Solution Approach 1:
Guiding surfaces are introduced as intermediary elements between the feed surfaces and the elevator. These guiding surfaces control the rolling motion and orientation of rolls during transfer, preventing uncontrolled sliding and interference between rolls in different layers. The guiding surfaces act as mediators that ensure stable, interference-free stacking while maintaining efficient layered pack formation.
3Productivity
If an elevator is used to transfer layers of rolls, then layered packs can be formed, but high production rates are impossible due to elevator movement requirements
Solution Approach 1:
Multiple feed surfaces are merged into a single integrated forming unit that operates simultaneously. Instead of using one elevator that moves sequentially between layers, the invention combines multiple feed surfaces at different levels into one unified system where all layers are fed and stacked in parallel, eliminating the need for repeated elevator movements and achieving high production rates with reduced mechanical complexity.
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 enables high production rates for layered packs with reduced interference and maintenance, allowing for efficient handling and transportation of rolls while maintaining low operational costs.
Implementation Method 1
The receiving station 6 comprises an elevator 7 for transferring the layers of products fed from the feed surfaces 3, 4, 5 to a packaging machine
Implementation Method 2
The containment walls 21, 22 may be able to move towards one another, compressing the rolls 2 during said movement
Implementation Method 3
The feed surfaces 3, 4, 5 consist of conveyor belts driven by motor means
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A unit for forming packs of products for a packaging machine comprises at least three feed surfaces (3, 4, 5) for layers of products (2) and a receiving station (6) for the layers of products (2). The receiving station (6) comprises an elevator (7), mobile only between a position for loading the products (2) and a position for releasing the products (2), to transfer the layers of products (2) to a packaging machine (8). The three feed surfaces (3, 4, 5) comprise synchronisation means so that they simultaneously release the respective layers of products (2) onto the elevator (7).