Packaging System Misalignment Correction via Conveying Bar
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Solution Overview
Problem
Conventional packaging systems face challenges in accurately correcting misalignment of products during the packaging process, leading to unsatisfactory packaging and potential damage due to inadequate alignment correction, especially when products are light or deep, causing slipping issues and instability during conveyance.
Innovation Solution
A packaging system equipped with a detection unit to determine misalignment in both the conveying and width directions, and a control unit to adjust the conveying and film supply accordingly, ensuring precise positioning and alignment correction during the packaging process, including the use of a second conveying surface that can move within a specific range to correct misalignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a camera is used to detect misalignment before conveyance, then initial positioning accuracy is improved, but misalignment cannot be sufficiently corrected when the tray tilts during conveyance
Solution Approach 1:
The camera captures the tray position before conveyance to determine initial misalignment, and the conveying bar is positioned in advance based on this detection. This preliminary positioning action allows the system to anticipate and compensate for potential tilting during conveyance, ensuring the tray remains properly aligned throughout the packaging process.
Solution Approach 2:
The system uses camera detection to obtain feedback on tray misalignment, then adjusts the conveying bar position accordingly. This closed-loop feedback mechanism enables real-time correction of misalignment issues, ensuring that even if the tray tilts during conveyance, the packaging quality remains high.
2Manufacturing precision
If the conveying bar contacts the tray to correct misalignment, then positioning accuracy is improved, but the tray may tilt or become unstable especially when materials are light
Solution Approach 1:
The conveying bar is designed with a specific contact structure that applies force locally to the tray's rear end. This localized contact approach corrects misalignment without causing the tray to tilt, especially when materials are light. The conveying bar's geometry and contact point are optimized to maintain tray stability while achieving precise positioning.
Solution Approach 2:
The system determines the conveying bar position in advance based on camera detection of tray misalignment. By pre-positioning the conveying bar to account for potential tilting, the system prevents stability issues before they occur, rather than reacting after the tray has tilted during conveyance.
3Manufacturing precision
If the tray is moved towards the center according to calculated misalignment, then widthwise alignment is improved, but misalignment changes during conveyance render correction insufficient
Solution Approach 1:
The system calculates and applies widthwise alignment correction in advance by positioning the conveying bar appropriately before conveyance begins. This preliminary correction accounts for potential misalignment changes during conveyance, ensuring that the tray maintains proper widthwise alignment throughout the packaging process.
Solution Approach 2:
The camera provides feedback on the tray's widthwise misalignment, which is then used to adjust the conveying bar position. This feedback loop ensures that the correction applied is accurate and accounts for any changes that occur during conveyance, maintaining reliable final packaging alignment.
4Productivity
If the conveying bar position is set in advance for each tray, then conveyance efficiency is improved, but misalignment cannot be resolved during the conveying process
Solution Approach 1:
The system determines the conveying bar position in advance based on camera detection of tray misalignment. This preliminary positioning allows the conveying bar to correct misalignment during the natural conveyance motion, maintaining high productivity while achieving precise alignment correction without requiring additional adjustment steps.
Data Source
AI summary
A packaging system is disclosed that packages a product by supplying the product onto a lifter by means of a supply device, pushing the product on the lifter up to a packaging station, and covering the top surface of the product with a film. The packaging system includes a conveying unit that contacts the rear end in the conveying direction of the product on the supply device and configured to convey the product onto the lifter, a detection unit configured to determine the amount of misalignment of the product in the conveying direction and/or the width direction that is orthogonal to the conveying direction, while the product is being conveyed by the conveying unit, and a control unit configured to control the devices in the system to perform in accordance with the amount of misalignment.