Packer Machine Sensor Barrier for Safe Material Loading
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Solution Overview
Problem
The production of rigid cigarette packs with a hinged lid poses safety hazards for operators due to the need to stop the packer machine for loading materials, either by stopping all moving parts or increasing the machine's bulk by relocating the loading opening, which affects productivity and safety.
Innovation Solution
A packer machine with a sensor device that creates a virtual barrier around the loading opening, allowing continuous operation of the wrapping line while automatically stopping and restarting the transfer unit to ensure operator safety without requiring physical doors or relocating the loading opening, thus maintaining productivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If the loading opening is closed with a physical door provided with sensors to protect operator safety, then operator safety is improved, but the packer machine must stop every time materials are loaded, resulting in reduced productivity
Solution Approach 1:
The patent replaces the mechanical door system with an optical sensor field that creates a virtual barrier. The sensor device emits signals that detect the presence of objects (bundles of blanks) in the loading opening without requiring physical obstruction. This allows the machine to distinguish between safe conditions (opening empty or containing only blanks) and dangerous conditions (operator presence), eliminating the need to stop the machine for safety while still protecting operators.
2Object-affected harmful factors
If the loading opening is shifted far from the moving parts and material treatment zone to protect operator safety, then operator safety is improved, but the bulk of the packer machine is remarkably increased
Solution Approach 1:
The patent introduces an intermediary sensor field that mediates between the loading opening and the moving parts. This virtual barrier allows the loading opening to remain in its optimal position close to the material treatment zone while still providing safety protection. The sensor field acts as an intermediary detection layer that monitors the space without requiring physical distance or additional machine bulk.
3Object-affected harmful factors
If the packer machine stops all moving parts when the loading opening is opened to lock moving parts, then operator safety is improved, but the average productivity is reduced
Solution Approach 1:
The patent implements a dynamic safety system that adapts the machine's response based on real-time detection. Instead of a static stop-all-movements approach, the sensor device continuously monitors the loading opening and only triggers safety interventions when actual danger is detected (operator presence). Normal material loading operations proceed without interruption, while safety is maintained through active monitoring. This dynamic approach minimizes unnecessary downtime while preserving safety.
Data Source
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AI summary
A packer machine (1) and a wrapping method to produce a pack (2). The following are present: a wrapping line (7), which is provided with a plurality of movable wrapping devices (8); a first actuator (9), which is designed to cause the movable wrapping devices (8) to move; an insertion station (S1), which is arranged along the wrapping line (7) and where the wrapping line (7) receives one single wrapping material to be folded; an input station (S2), which is separate from the wrapping line (7) and has a loading opening (15); a transfer unit (12), which is designed to receive wrapping material groups in the input station (S2) and to direct the wrapping material towards the wrapping line (7); and at least one second actuator (13) which is independent of the first actuator (9) and is designed to move the transfer unit (12); a sensor device (16), which is designed to detect the presence of a body in the loading opening (15) of the input station (S2); and a control unit (20), which is configured to stop, when the packer machine (1) is working, the sole second actuator (13), thus allowing the first actuator (9) to normally operate, if the sensor device (16) detects the presence of a body in the loading opening (15) and to automatically restart the second actuator (13) if the sensor device (16) stops detecting the presence of a body in the loading opening (15).