Product Grouping Apparatus with Orthogonal Conveyor and Series Compaction
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Solution Overview
Problem
Current packaging systems for disposable absorbent sanitary articles are limited by the need for two separate packaging machines to achieve high production speeds, leading to increased costs, space requirements, and limitations in package size due to the distance between extractor devices.
Innovation Solution
An apparatus that forms groups of products by using a conveyor system with orthogonally oriented septa and an extractor element to create groups, which are then compacted in series by dual compacting devices before being packaged, allowing for efficient packaging of up to 2000 products per minute with a single machine.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single packaging machine is used, then device complexity and cost are reduced, but production speed is limited due to extractor device spacing constraints
Solution Approach 1:
The extraction system is segmented into multiple extraction stations arranged in series along the conveyor path, allowing each station to independently extract groups of products at different positions. This segmentation enables a single packaging machine to handle multiple extraction points simultaneously, increasing production speed without adding multiple complete packaging machines.
Solution Approach 2:
The invention transitions from a single extraction point to multiple extraction stations distributed along the conveyor's length (adding a spatial dimension). This dimensional expansion allows the system to process multiple groups of products in parallel through different extraction stations, effectively increasing throughput while maintaining a single packaging machine configuration.
2Productivity
If two packaging machines are used in parallel, then production speed increases, but device complexity, cost, and space requirements increase
Solution Approach 1:
A single packaging machine is designed to perform multiple functions by serving multiple extraction stations. The packaging machine can simultaneously or sequentially package groups of products extracted at different stations, making it a multi-functional device that replaces what would traditionally require two separate machines.
Solution Approach 2:
The system maintains continuous operation by having multiple extraction stations feeding the packaging machine in sequence. While one extraction station is being serviced, another can be preparing the next group of products, ensuring continuous useful action without idle time and achieving high production speeds with a single machine.
3Quantity of substance
If packages contain fewer products, then market demand is met, but production speed is limited by packaging machine capacity
Solution Approach 1:
The product flow is segmented into multiple groups at different extraction stations, each group destined for a package. This segmentation allows the system to handle smaller package sizes (meeting market demand) while processing multiple groups simultaneously through different stations, maintaining high production speed despite reduced products per package.
Data Source
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AI summary
An apparatus for forming groups of products, comprising: - an inlet line (14) arranged to advance individual products (P) aligned along a first direction (X), - a conveyor (18) having a plurality of seats (20) for receiving respective products (P) from said inlet line (14) and movable along a second direction (Y) orthogonal to said first direction (X), - an extractor element (28) movable cyclically along an extraction direction (A) parallel to said first direction (X) and arranged to extract a first and a second group of products (G) from said conveyor (18) at each cycle, and - at least one compacting device (30, 32) comprising a fixed central wall (34, 44) and two side walls (36, 46) movable cyclically with respect to the central wall (34, 44) between an open position and a closed position, wherein said side walls (36, 46) and said fixed wall (34, 44) define two compacting zones (37, 47) for receiving respective groups of products (G) from said conveyor (18), wherein said side walls (36, 46) compact said groups of products (G) against the central wall (34, 44) during movement from the open position to the closed position.