Plug Plate Dispensing Assembly with Drive Roller
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Solution Overview
Problem
The existing plug plate dispensing processes are laborious and time-consuming, particularly in manufacturing where self-adhesive plug plates need to be manually removed from sheet stock, slowing down the manufacturing process.
Innovation Solution
A plug plate dispensing assembly comprising a base member, risers, cross members, and a drive roller that peels plug plates from a sheet stock as it moves through the assembly, automating the removal process by using a reel support member and a drive roller to frictionally engage and rotate the sheet stock, causing the plug plates to detach.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual removal of plug plates is used, then the plug plates can be removed without damage, but the manufacturing process becomes laborious and time-consuming
Solution Approach 1:
The patent replaces the manual mechanical removal process with an automated mechanical system consisting of a drive roller, cross members, and reel support. The drive roller frictionally engages the sheet stock and rotates it, while the cross members guide and support the plug plates during automated removal, eliminating the need for manual handling while maintaining safe plug plate detachment.
Solution Approach 2:
The system enables self-service automation where the sheet stock itself is fed through the assembly and frictionally engaged with the drive roller to automatically peel off the plug plates. The material being processed (sheet stock) performs part of the feeding function, reducing the need for additional actuators or complex control systems.
2Productivity
If automated plug plate removal is implemented, then manufacturing efficiency increases, but the device complexity increases
Solution Approach 1:
The automated removal system is segmented into distinct functional components: a drive roller for rotating the sheet stock, cross members (apex, central, lower) for guiding and supporting the plug plates, and a reel support member for holding the plug plate reel. This segmentation allows each component to perform its specific function independently, making the overall system easier to design, manufacture, and maintain despite the automation.
Solution Approach 2:
The cross members serve multiple functions simultaneously: they guide the sheet stock, support the plug plates during removal, and maintain proper tension and alignment throughout the automated peeling process. The reel support member both holds the reel and facilitates its rotation during the automated removal cycle, reducing the total number of components needed.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution significantly reduces the time required to remove plug plates, automating the process and increasing manufacturing efficiency by allowing the plug plates to be peeled automatically as the sheet stock is fed through the assembly.
Implementation Method 1
when the sheet stock is frictionally engaged with the drive roller, rotation of the drive roller can cause one or more of the plurality of plug plates to at least partially detach from the sheet stock
Data Source
AI summary
In one embodiment, a plug plate dispensing assembly can include a first riser, a second riser, an apex cross member, a lower cross member, a central cross member, and a drive roller. The apex cross member, the lower cross member, and the central cross member can be coupled to the first riser and the second riser, and can extend from the first riser to the second riser. When the sheet stock is fed between the lower cross member and the apex cross member, over the apex cross member, and between the apex cross member and the central cross member, and when the sheet stock is frictionally engaged with the drive roller, rotation of the drive roller can cause one or more of the plurality of plug plates to at least partially detach from the sheet stock as the sheet stock passes over the apex cross member.