Pillow Bag Sorting System with Dynamic Speed Control
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Solution Overview
Problem
Existing case packer systems for pillow bags containing salty snacks face challenges in ensuring proper filling of containers due to variable manufacturing rates and the risk of incomplete or incorrect placement of bags, leading to economic losses and customer dissatisfaction, especially during marketing campaigns with combined products.
Innovation Solution
A system comprising loading stations with conveyor belts and robotic gripping means, along with a support plane with movable panels, allows for precise sorting and placement of pillow bags and gadgets into containers, ensuring the correct number is filled independently of the case packer's manufacturing rate, using detection signals to adjust the placement speed and position of bags and gadgets.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If a conveyor belt is used to transport pillow bags from the bagging machine to the case packer, then automation is improved and manual transfer is eliminated, but the variable manufacturing rate of the bagging machine causes incomplete filling of containers
Solution Approach 1:
The system performs preliminary actions by pre-positioning containers on the support plane before they reach the filling position, and by advance positioning pillow bags on the conveyor belt. This allows the system to prepare all necessary elements in advance, enabling reliable container filling even when the bagging machine operates at variable speeds, thus resolving the contradiction between automation and filling completeness.
Solution Approach 2:
The system incorporates feedback mechanisms through detection devices that monitor the position and status of both containers and pillow bags in real-time. This feedback information is used to dynamically adjust the timing and positioning of filling operations, ensuring that containers are filled completely and accurately despite variable bagging rates, thereby maintaining reliability while preserving automation.
2Manufacturing precision
If pushing devices or flow deflectors are used to re-orient pillow bags, then bag orientation control is improved, but the mechanical action damages the bags or the low bulk density snacks contained therein
Solution Approach 1:
The system replaces mechanical re-orientation devices (pushing devices, flow deflectors) with a non-mechanical positioning approach. Pillow bags are gently guided into their correct orientations using the conveyor belt's controlled movement and precise positioning mechanisms, avoiding any vigorous mechanical contact that would damage the bags or their low bulk density contents, thus resolving the contradiction between orientation control and product protection.
3Productivity
If the case packer operates at high speed to match the bagging machine's variable manufacturing rate, then productivity is improved, but some bags fall out of the line and cannot be inserted into containers
Solution Approach 1:
The system employs dynamic adjustment capabilities where the conveyor belt speed and container movement speed can be independently controlled and adjusted in real-time. This dynamic control allows the system to synchronize bag insertion with container arrival, ensuring that bags are reliably inserted even when operating at high speeds, thus resolving the contradiction between productivity and insertion reliability.
Solution Approach 2:
The support plane acts as an intermediary mechanism between the conveyor belt and the container filling process. It provides a stable intermediate position where bags can be securely positioned and transferred to containers, preventing bags from falling out of the line even at high operating speeds, thereby maintaining reliability while preserving high productivity.
4Adaptability or versatility
If manual operators are used to transfer pillow bags to containers, then flexibility and adaptability are improved, but labor costs increase and operational efficiency decreases
Solution Approach 1:
The system implements self-service automation where the conveyor belt automatically transports pillow bags, the support plane automatically positions containers, and the filling mechanism automatically places bags into containers without requiring manual operators. This self-service approach eliminates labor costs while maintaining operational flexibility through programmable control, thus resolving the contradiction between adaptability and productivity.
Data Source
Figure 1
AI summary
The present invention relates to a system and a method for sorting a plurality of pillow bags (100, 101, ..., 100x) containing salty products, comprising a loading station (2) having a conveyor belt (4) extending by a predetermined length (L) along a first horizontal lying plane (X), first motor means (2A) to move said conveyor belt (4) with a first advancement speed (v1) so as to transport a row of pillow bags (100, 101, ..., 100x) from a loading position to an unloading position; an ordering station (3) having a support plane (5) extending along a second horizontal lying plane (X') and intended to receive and support a plurality of pillow bags (100, 101, ..., 100x), second motor means (3A) to move said support plane (5) with a second advancement speed (v2) from a loading position to an unloading position; a plurality of panels (6,7) active on said support plane (5) to define a plurality of containing spaces (8), each of which being intended to contain a predetermined plurality of pillow bags (100, 101, ..., 100x); gripping means (9) configured to grasp a pillow bag at a time from said row of pillow bags (100, 101, ..., 100x) present on said conveyor belt (4) and to put it into a containing space (8) defined on said support plane (5); detecting means (10) of the spatial position of each bag of said row of pillow bags (100, 101, ..., 100x), said detecting means (10) being associated to said conveyor belt (4) in the proximity of said loading position and configured to generate a passage signal (S1) upon the passage of each pillow bag (100, 101, ..., 100x) present on said conveyor belt (4), said passage signal (s1) being representative of the time instant at which said pillow bag (100, 101, ..., 100x) has passed; processing and driving means (11) in signal communication with said detecting means (10) and electrically connected with said gripping means (9) and with said second motor means (3A), said processing and driving means (11) comprising a firmware configured for: - processing said passage signal (S1) as a function of said first advancement speed (v1) and said length (L) of said conveyor belt (4) so as to generate a position signal (S2) identifying the position taken by each of said pillow bag (100, 101, ..., 1 00x) with respect to said conveyor belt (4) and - generating a driving signal (S3) to drive said second motor means (3A) to change said second advancement speed (v2) as a function of said position signal (S2).