Packaging Machine Intermediate Storage Decouples Clocked and Continuous Conveyors
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Solution Overview
Problem
Existing packaging machines for pharmaceutical products in primary packaging struggle to maintain effective stacking on continuously driven conveyor devices when individual products are fed in a clocked fashion, often experiencing disruptions in the product flow.
Innovation Solution
The introduction of an intermediate storage device, or clipboard, which decouples the clocked first conveyor from the continuously driven second conveyor, allowing for orderly product transfer and handling of defective products, enabling efficient stacking with a single transfer device and maintaining compact machine dimensions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a clocked first conveyor device feeds individual products to a continuously driven second conveyor device, then product transfer is possible, but disruptions in product flow occur during stacking
Solution Approach 1:
A buffer device is introduced as an intermediary element between the clocked first conveyor device and the continuously driven second conveyor device. This buffer temporarily stores individual products or small groups of products, decoupling the synchronous operation of the first conveyor from the continuous operation of the second conveyor. The buffer absorbs flow disruptions and ensures continuous product supply to the stacking zone, resolving the contradiction between maintaining productivity and ensuring flow reliability.
2Reliability
If multiple transfer devices are used to transfer products from clocked first conveyor to continuously driven second conveyor, then product transfer reliability improves, but device complexity increases
Solution Approach 1:
The buffer device serves as a mediating storage element that eliminates the need for multiple complex transfer devices. By temporarily holding products, the buffer allows a single transfer device to operate at its own rhythm, picking products from the buffer rather than directly from the clocked conveyor. This simplifies the system architecture while maintaining reliable product transfer.
Solution Approach 2:
The buffer device performs preliminary storage of products before they reach the transfer zone. This advance preparation allows the transfer device to operate continuously without waiting for the clocked conveyor, improving transfer reliability while reducing the need for multiple coordinated transfer devices.
3Reliability
If an intermediate storage device is introduced to decouple conveyors, then product flow stability improves, but machine dimensions increase
Solution Approach 1:
The buffer device is positioned above the first conveyor device, utilizing vertical space rather than horizontal space. This three-dimensional arrangement allows the buffer to decouple the conveyors and stabilize product flow without significantly increasing the machine's horizontal footprint, thus resolving the contradiction between flow stability and compact dimensions.
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 ensures uninterrupted material flow, reduces equipment and control technology requirements, and adapts cycle times to handle multiple products, enhancing the packaging efficiency and flexibility while maintaining compact dimensions.
Implementation Method 1
there are two transfer devices, each designed as a vacuum suction arm. The transfer devices alternately remove products from the first conveyor device and place them on the second conveyor device
Data Source
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AI summary
A packaging machine (1) is used for packaging products (2) that are pharmaceutical products contained in primary packaging, in particular blister packs. The packaging machine (1) has a timed, driven first conveying unit (3, 4) with which individual products (2) are conveyed. The products (2) are temporarily stored in an intermediate storage unit (7), removed from the intermediate storage unit (7) by a transfer device (12), and placed onto a second conveying unit (13) to form stacks of products (2). The second conveying unit (13) is continuously driven and serves to convey the stacks of products (2). The stacks of products (2) are then placed into suitable secondary packaging, in particular folding cartons.