Packaging Slide Element for Tray Insertion

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Solution Overview

Problem

Existing methods for packaging products, such as biscuits, into trays are slow, expensive, and prone to underfilling or overfilling due to manual handling and lack of precise control, especially when dealing with sensitive or irregularly shaped items.

Innovation Solution

A fully automatic system that conveys products in a continuous stream, stacks them on an inclined plane, and uses a slide element to actively push and insert products into trays, allowing for precise placement and handling of various shapes and sizes, with optional manual intervention for quality control.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If manual handling is used to insert products into trays, then products can be handled gently, but the process is slow and expensive

Engineering Contradiction:

Improvegentle product handlingVSAvoidpackaging speed

Core Design Contradiction:

Ease of operationVSProductivity

Solution Approach 1:

The system uses self-contained automated mechanisms (conveyor belts, pusher devices, tray feeders) that operate autonomously to insert products into trays, eliminating manual labor while maintaining gentle handling through controlled mechanical motion

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

Manual mechanical handling is replaced with automated mechanical systems including conveyor belts for product transport, pusher devices for precise insertion, and tray feeders for automated tray supply, achieving both speed and gentleness through engineered control

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Productivity

If automated conveyor systems are used to insert products into trays, then packaging speed increases, but products may be misoriented or trays may be underfilled/overfilled

Engineering Contradiction:

Improvepackaging speedVSAvoidproduct placement accuracy

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The system incorporates sensors and control mechanisms that monitor product position, orientation, and tray filling status, automatically adjusting the conveyor and pusher operations to maintain precise placement and prevent underfilling or overfilling

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The conveyor system and pusher devices are designed with dynamic control capabilities, allowing real-time adjustment of speed, position, and force to accommodate variations in product characteristics while maintaining accurate placement

Inventive Principle:

Principle #15Dynamics

3Measurement precision

If suction heads are used to grip and insert products, then individual product insertion is achieved, but the method is limited to specific product types and has short cycle times

Engineering Contradiction:

Improveindividual product controlVSAvoidproduct type compatibility

Core Design Contradiction:

Measurement precisionVSAdaptability or versatility

Solution Approach 1:

The pusher device and conveyor system are designed with universal applicability to handle various product types including flat products, baked goods, and irregularly shaped items, replacing the product-specific suction head approach with a general-purpose mechanical pushing mechanism

Inventive Principle:

Principle #6Universality (Multi-functionality)

4Productivity

If products are conveyed in a continuous stream, then packaging efficiency increases, but precise individual product insertion becomes difficult

Engineering Contradiction:

Improvecontinuous packaging flowVSAvoidindividual product insertion accuracy

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The continuous product stream is segmented into individual products through the pusher device, which separates and positions each product individually as it moves along the conveyor, enabling precise insertion while maintaining continuous flow

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Products are pre-positioned and oriented on the conveyor belt before reaching the insertion point, with the pusher device ready to insert them individually into trays, ensuring both continuous flow and precise placement

Inventive Principle:

Principle #10Preliminary action

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 significantly reduces personnel costs, increases hygiene standards, and achieves high cycle rates, enabling efficient packaging of a wide variety of products with reliable operation and minimal risk of damage, capable of processing up to 300 products per minute.

Implementation Method 1

stacking taking place on an inclined or inclined plane

Methodology Applied

Scientific EffectGravity: Gravitation

Data Source

PatentEP2354010B1Method and device for packaging products

Publication Date: 2013.10.09 BAHLSEN GMBH & CO KG

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AI summary

The method involves supplying products (1) in a continuous product stream. The individual products are stacked in an inclined plane (3), and empty trays (4) are advanced below the inclined plane. The lowest/front product is ejected from a product stack (5) by a slide element (6) and is moved into the trays. The trays are forwardly moved gradually around a thickness of the product, and the slide element is arranged on the product and is actuatable by a servo-drive (10). The trays are formed in form of open shells. An independent claim is also included for a device for packing products.