Packaging Device Layer Formation Eliminates Buffers
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Solution Overview
Problem
Existing packaging processes are inefficient due to the need for buffers and multiple conveyor lines, which increase complexity and reduce speed, making it difficult to achieve high production volumes with flexibility in packaging formats.
Innovation Solution
A packaging device and process that eliminates the use of buffers by forming layers directly on the gripping device of the transfer device, allowing for continuous conveyor operation and increased flexibility in packaging formats, including the ability to handle different layer sizes and patterns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If buffers and multiple conveyor lines are used in existing packaging processes, then articles can be handled and transferred, but device complexity increases and operating speed decreases
Solution Approach 1:
The patent extracts and eliminates the buffer component from the packaging system. By forming layers directly on the gripping device of the transfer device, the system removes the need for intermediate buffer storage, thereby reducing device complexity while maintaining continuous operation capability.
Solution Approach 2:
The patent merges the layer formation function with the transfer device's gripping device. Instead of having separate buffer and conveyor components, the gripping device directly forms layers and transfers articles in one integrated operation, reducing the number of conveyor lines and buffers needed.
2Ease of operation
If buffers are used to prepare layers for insertion, then article handling is enabled, but the packaging apparatus becomes less compact and more complex
Solution Approach 1:
The gripping device of the transfer device is designed to perform multiple functions: it picks up articles from the conveyor line, forms layers in the desired configuration, and transfers them to packaging containers. This multi-functionality eliminates the need for dedicated buffer devices while maintaining flexibility in handling different packaging formats.
Solution Approach 2:
The system uses a continuous conveyor line operating at variable speeds that can adapt to different packaging requirements. The transfer device dynamically adjusts its operation to form layers of different sizes and patterns directly on the moving conveyor, eliminating static buffer structures.
3Productivity
If multiple conveyor lines and buffers are employed, then article transfer is achieved, but production volume and speed are reduced
Solution Approach 1:
The patent implements continuous operation by eliminating buffers that would require loading and unloading cycles. The single conveyor line operates continuously with the transfer device forming and transferring layers in real-time, eliminating idle time and maximizing productive action throughout the system.
Solution Approach 2:
The layer formation occurs preliminarily on the gripping device during the transfer operation itself, rather than requiring separate preliminary buffer preparation. This integrates the layer formation time into the transfer time, eliminating additional time loss.
Data Source
AI summary
A packaging device and a process for packaging articles arranged according to a predetermined pattern and supplied on a conveyor line are presented, where buffers for the preparation of layers to be packaged are eliminated, while maintaining a high degree of flexibility for a wide range of formats. The packaging device includes one or more transfer devices that pick up the articles and deposit them in layers. The transfer devices have a handling member connected to a respective gripping device, both movable along three orthogonal axes. Each gripping device has gripping elements to pick up an article from the conveyor line. The gripping elements are arranged to form, on each gripping device, a single layer of articles. Each layer is obtained with one or more pickings from the conveyor line, in order to place the articles in a single operation in a respective container of the flow.