Post Compression Carton Rejection System
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
In high-speed carton assembly systems, improperly glued cartons often come apart during shipping due to machine stoppages, leading to product damage and loss, and manual defect removal is inefficient, especially in automated lines.
Innovation Solution
A post compression carton rejection system that includes an in-line conveyor system with sensors and a programmable controller to automatically identify and separate defective cartons by creating gaps and using a dump gate to reject them, ensuring all uncompressed cartons are removed and allowing good ones to proceed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual defect removal is used by operators, then defects can be removed, but productivity decreases and consistency is poor
Solution Approach 1:
The system enables self-service automation where the conveyor system automatically identifies, isolates, and removes defective cartons without human intervention. Sensors detect defects, the controller coordinates gap creation and dump gate activation, eliminating reliance on manual operator inspection and removal while maintaining high processing speeds.
Solution Approach 2:
The patent replaces the manual mechanical system of operator inspection and defect removal with an automated sensing and control system. Optical or sensor-based detection substitutes human visual inspection, while automated actuators control the dump gate and gap creation mechanisms, replacing manual physical intervention entirely.
2Productivity
If automated rejection system is implemented, then productivity increases and consistency improves, but device complexity increases
Solution Approach 1:
The controller serves multiple functions: it receives sensor signals, determines defect presence, coordinates gap creation timing, controls dump gate actuation, and manages conveyor speed variations. This multi-functionality reduces the need for separate dedicated components for each function, thereby managing system complexity while achieving automated defect removal.
Solution Approach 2:
The system merges the defect detection function, gap creation mechanism, and defect removal function into a single integrated automated rejection system. The infeed conveyor, outfeed conveyor, dump gate, and controller work as a unified system rather than separate independent mechanisms, simplifying the overall device architecture.
3Reliability
If gaps are created before and after defective cartons, then defect removal accuracy increases, but processing time increases
Solution Approach 1:
The system uses periodic action by creating gaps at specific intervals rather than continuously stopping the conveyor. The conveyor operates continuously, creating temporary gaps only when defects are detected, allowing defect removal while minimizing disruption to the overall processing flow and reducing time loss.
Solution Approach 2:
The system performs preliminary action by creating the gap before the defective carton reaches the dump gate position. This allows the defective carton to be isolated and removed during its transit along the outfeed conveyor, rather than stopping the entire system at the moment of defect detection, thereby reducing processing time interruption.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A post compression carton rejection system comprise a frame adapted to be supported between the compression conveying section and the packing system; an infeed conveyor is mounted to the frame and has an infeed belt for transporting folded and glued cartons from the compression conveying section and an infeed drive for driving the infeed belt; an outfeed conveyor is mounted to the frame between the infeed conveyor and a conveyor exit proximate the packer, in use, and comprises a nose extension conveyor having an outfeed belt including a dump gate controllably retractable at the conveyor exit to selectively dump folded and glued cartons, an outfeed drive for driving the outfeed belt and a dump gate actuator for opening and returning the dump gate; a controller operatively controls the infeed drive, the outfeed drive and the dump gate.