Parallel Stacker Conveyor System for Register-Accurate Hygiene Product Packaging
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Solution Overview
Problem
Existing systems for packaging hygiene products, such as paper handkerchiefs and sanitary napkins, face challenges in achieving high throughput and production rates while maintaining register-precise feeding and minimizing mechanical stress on product stacks, which are costly and prone to distortion due to the use of constant-speed conveyor belts and expensive suction systems.
Innovation Solution
A system with at least two parallel stacker units is implemented, where one stacker unit has a one-piece conveyor with a programmable servo drive for gentle handling, and the other has a multi-part conveyor with independently controlled units to ensure register-accurate and synchronized delivery of product stacks to the packer, reducing mechanical stress and equipment costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If constant-speed conveyor belts are used to transport product stacks from parallel stacker units, then throughput and production rates can be increased, but mechanical stress on product stacks increases and register-precise feeding becomes difficult to maintain
Solution Approach 1:
The conveyor system uses servo drives with programmable movement profiles that dynamically adjust speed and acceleration parameters. The conveyor can operate at high speeds for throughput while using controlled acceleration/deceleration phases to minimize mechanical stress on product stacks during transfer operations.
Solution Approach 2:
The conveyor system is divided into multiple independently controllable conveyor sections, each with its own servo drive and movement profile. This allows different sections to be optimized for different functions: some sections for high-speed transport, others for gentle product handling and positioning.
2Productivity
If multiple parallel stacker units are connected to a common packaging unit, then productivity increases, but synchronization and register-accurate feeding become more complex
Solution Approach 1:
The system incorporates sensors and control systems that monitor the position and status of product stacks from multiple stacker units. This feedback information is used by the central control to dynamically adjust conveyor speeds and timing, ensuring register-accurate feeding to the packaging unit even with variable stacker production rates.
Solution Approach 2:
The conveyor system serves multiple functions: it transports product stacks from different stacker units, buffers products from variable production rates, synchronizes multiple product streams, and positions stacks with register accuracy for packaging. This multi-functionality is achieved through a unified programmable control system.
3Area of stationary object
If belt conveyors run at an angle to deflect product stacks 90 degrees, then space is utilized efficiently, but product stacks become distorted and mechanical load increases
Solution Approach 1:
The system replaces mechanical belt deflection with vertical product drop and guide rail systems. Product stacks are conveyed horizontally, then dropped vertically under gravity into positioning stations with minimal mechanical contact, eliminating the trapezoidal distortion caused by angled belts while achieving the same 90-degree direction change.
4Measurement precision
If suction systems are used to hold product stacks in place during deflection, then register-accurate positioning is achieved, but equipment costs increase
Solution Approach 1:
The system extracts and eliminates the need for expensive suction systems by using gravity-based vertical drops and mechanically simple guide rails for positioning. Register accuracy is achieved through programmable conveyor timing and positioning rather than active suction holding.
Data Source
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AI summary
The invention relates to equipment (1) for producing packed product stacks (8) of folded or unfolded cut products of paper, cellulose or similar, particularly of hygiene products, having at least two stacker units (6) connected in parallel on the product stream side for forming the product stacks (8) from the cut product, downstream of which a common packaging unit (2) is connected on the product stream side by means of a conveying system (10). According to the invention the conveying system (10) comprises a first, single-part conveyor (20) assigned to one of the stacking units (6) and a second multiple-part conveyor (22) assigned to a second stacker unit (6).