Packaging System Seats for Multi-Line Unit Formation
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Solution Overview
Problem
Existing packaging systems face challenges in forming units of packages from multiple lines without errors, leading to incorrect numbers of packages, which disrupts the packaging process and requires complex management of rejects and malfunctions, especially when multiple lines are interrelated.
Innovation Solution
A method and system that includes seats for accommodating packages, a store for package correction, and control and command means to adjust the number of packages in each seat to ensure each unit contains a multiple of a predetermined number, allowing for real-time correction and transfer to compartments, thereby ensuring accurate packaging without rejects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If packages from multiple lines are grouped together to form units, then productivity increases, but the risk of forming incorrect units increases due to rejects and malfunctions
Solution Approach 1:
The system implements feedback mechanisms through control and command means that continuously monitor the number of packages in each seat and automatically adjust by transferring packages between seats and store to correct any deviations from the target number n, ensuring unit correctness while maintaining high packaging speed
Solution Approach 2:
The system performs self-correction by automatically detecting and correcting package number deviations in each seat through automated transfer operations between seats and store, eliminating the need for external intervention or complex reject management while maintaining productivity
2Reliability
If a reintegrating store is used to correct incomplete groups, then unit correctness is maintained, but device complexity increases
Solution Approach 1:
The store serves multiple functions: it acts as a buffer for packages, a source for correcting incomplete groups, and a destination for removing excess packages. This multi-functionality reduces the need for separate correction mechanisms and simplifies the overall system structure while maintaining unit correctness
3Reliability
If packages are transferred between seats and store for correction, then unit correctness is ensured, but loss of time increases due to additional transfer operations
Solution Approach 1:
The system maintains continuous operation by performing package transfers between seats and store during normal packaging operations without stopping the production line. The control system manages transfers in real-time, ensuring that correction operations occur concurrently with packaging activities, thus minimizing time loss while maintaining unit correctness
Data Source
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AI summary
A system (100) for forming units (B) of packages (A) to be packed, each comprising a multiple of a number n of packages (A); the system (100) comprises seats (1) for accommodating stacks of packages (A), a store (2) of packages (A), loading means (3) for loading the seats (1) with stacks of packages (A), displacement means (4) for displacing the packages (A) from the store (2) to the seats (1) and vice versa, movement means (6) for moving compartments (61) to receive packages (A), transfer means (5) for transferring the packages (A) from the seats (1) to the compartments (61) and control and command means (7). The control and command means (7) are advantageously configured so that the number of packages (A) in each seat (1) is equal to the number n or to zero and the movement means (6) are configured to make the compartments (61) available in sequence on the base of the seats (1) with a number of packages (A) equal to the number n. Also described are a method for forming units (B) of packages (A) from two or more lines (C) and a computer program.