Packaging Storage Table Sensor Control for Gap Prevention
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Solution Overview
Problem
In packaging systems, storage tables face challenges in maintaining continuous operation due to slip effects during infeed, leading to gaps between packaging rows when storage lines are emptied, which disrupt subsequent processing steps, such as feeding to a drinking straw applicator.
Innovation Solution
A storage table design with independent control of transport devices and non-contact sensors at the discharge end to prevent gaps by stopping packaging rows just before the discharge end, ensuring precise positioning and minimizing the distance between adjacent packages, and using a bypass storage line to maintain continuous operation during downstream faults.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If packaging rows are fed into storage lines with a large distance from the downstream end to account for slippage effects, then slippage is accommodated, but gaps occur between packaging rows when storage lines are emptied
Solution Approach 1:
A sensor system detects the position of packaging rows in real-time and provides feedback to the control device, which adjusts the transport device to stop the packaging row at a predetermined position just before the downstream end of the storage line, preventing gaps while accommodating slippage effects
Solution Approach 2:
The control device is programmed with advance knowledge of the slippage distance and automatically compensates for it by positioning the packaging row to stop just before the downstream end, rather than allowing it to slip and create a gap
2Productivity
If the processing rate of packaging stations is increased to improve system efficiency, then productivity increases, but disruptions at individual devices occur more frequently
Solution Approach 1:
Storage lines are positioned and controlled to stop just before the downstream end, creating a buffer zone that cushions against disruptions and prevents gaps that would cause interruptions in downstream packaging devices
3Productivity
If storage lines are emptied completely to maximize space utilization, then storage capacity is optimized, but gaps between packaging rows disrupt subsequent processing
Solution Approach 1:
The mechanical slippage-based positioning is replaced with a sensor-controlled positioning system that uses detection and control mechanisms to achieve precise stopping positions, eliminating the need for slippage compensation through mechanical means
Data Source
Figure 1
Figure 2a~2b
Figure 2c
AI summary
The invention relates to a storage table (2) for a packaging system (1). The storage table (2) has an inlet (3), an outlet (4) and at least two storage lines (5a-h) that can be loaded with packaging (6) separately and are arranged between the inlet (3) and the outlet (4), wherein a transport device is assigned to each of the at least two storage lines (5a-h) for transporting the respective packaging (6).According to the invention, a non-contact sensor (7) is provided in a downstream end region of the at least two storage lines (5a-h) for detecting the presence or absence of packaging (6) in the downstream end region of the respective storage lines (5a-h), wherein a control device is also provided for controlling the transport devices assigned to the at least storage lines (5a-h), wherein the control device is designed to control the transport devices assigned to the storage lines (5a-h) depending on a detection result of the at least one sensor (7).