Packaging Machine On-Demand Tray Loading with Dual Rail Conveyor
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing container-forming machines are limited in their ability to handle containers with smaller dimensions transverse to the rail members and require accumulation of excess secondary containers, leading to increased expense, weight, and footprint, as well as limited on-demand loading capabilities.
Innovation Solution
A machine with a dual rail conveyor system and on-demand product loading system that uses smaller chains and an articulated chain cover to facilitate closer rail spacing, allowing for the formation and arrangement of secondary containers in various configurations, including 2×2, 2×4, or 2×6 arrays, and enables continuous feeding of secondary containers into a tertiary container without accumulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If large chains are used to push cartons along rails, then the chains can provide sufficient force to move multiple cartons, but the chains become relatively large in size which limits how closely the rails can be spaced
Solution Approach 1:
The patent extracts the pushing function from large chains and transfers it to smaller chains with pusher fingers. The chains are removed from the interior of the rails and repositioned on top of the rails, allowing the rails to be spaced closer together while still providing sufficient pushing force through the finger mechanism.
Solution Approach 2:
The patent introduces pusher fingers as an intermediary mechanism between the chains and the cartons. These fingers extend upwardly from the chains to contact and push the cartons, allowing the chains to be smaller while still providing adequate pushing force through the finger interface.
2Productivity
If rails are spaced far apart to accommodate large chains, then the chains can move cartons effectively, but the machine footprint increases and narrow containers cannot be handled
Solution Approach 1:
The patent extracts the chains from the interior space between rails and repositions them on top of the rails. This allows the rails to be spaced closer together, reducing the machine footprint and enabling handling of narrow containers while maintaining effective carton movement capability.
Solution Approach 2:
The patent changes the spatial arrangement by moving chains from a vertical positioning (inside rails) to a horizontal positioning (on top of rails). This dimensional reconfiguration allows closer rail spacing without compromising the chains' ability to move cartons effectively.
3Productivity
If secondary containers are accumulated before tray loading, then the tray loading station can be fed continuously, but additional conveyors and devices are required which increases expense, weight, and footprint
Solution Approach 1:
The patent enables continuous action by allowing the tray loading station to pull containers directly from the supply source on demand. The gate mechanism controls the flow to maintain continuous loading without requiring accumulation buffers or additional conveyor systems, simplifying the overall device architecture.
Solution Approach 2:
The tray loading station serves itself by directly accessing the supply source through the gate mechanism. Instead of requiring a separate accumulation system to feed the loading station, the system uses the gate to regulate direct flow from supply to loading, eliminating the need for additional intermediary devices.
4Productivity
If accumulation systems are added to feed tray loading station, then continuous feeding is possible, but the machine expense, weight, and footprint increase
Solution Approach 1:
The patent achieves continuous feeding action through the gate mechanism that regulates direct flow from the supply source to the tray loading station. This eliminates the need for accumulation buffers and additional conveyor systems, thereby reducing machine weight while maintaining feeding continuity.
Data Source
AI summary
A machine for filling a tertiary container with secondary containers is provided. The machine includes a frame and a tray loading station positioned to receive a plurality of streams of the secondary containers. The machine also includes a front gate at an upstream end of the tray loading station, the front gate moveable between a first position, in which the secondary containers are obstructed from passing downstream, and a second position, in which the secondary containers are not obstructed. The machine further includes a back stop proximate a downstream end of the tray loading station, the back stop moveable between a first, upstream position and a second, downstream position. The tray loading station is sized such that when a first row of secondary containers is positioned against the back stop in the first position, a portion of an upstream row of secondary containers is positioned directly above the front gate.