Retractable Stop Ramp for Pressware Stacking
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Solution Overview
Problem
Existing pressware stacking systems face issues with product loss and waste due to uneven conveyor speeds, improper placement, and damage caused by vertical stop gates, leading to system shutdowns and resource wastage.
Innovation Solution
A pressware stacking system featuring a conveyor with a stop ramp that can be inclined by a lifter to impede product flow, allowing shingling and continuous conveyance, thereby preventing product loss and damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the take-away table is stopped or slowed to prevent product loss during stack transfer, then product loss is reduced, but conveyor speed decreases and improper product placement occurs
Solution Approach 1:
A retractable barrier is introduced as an intermediary device between the conveyor and stacking surface. The barrier can be extended to block product flow and retracted to allow continuous conveyance, serving as a mediator that enables stack transfer without stopping the conveyor, thus resolving the contradiction between preventing product loss and maintaining conveyor speed
Solution Approach 2:
The barrier is designed to be dynamically adjustable - retractable and extendable - rather than fixed. This allows the system to adapt its state based on operational needs: extended during stack transfer to prevent product loss, and retracted during normal operation to maintain full conveyor speed and productivity
2Reliability
If a vertical stop gate system is used to prevent product advancement, then product flow control is improved, but physical injury to personnel and damage to products occur
Solution Approach 1:
Instead of using a vertical gate that moves downward to block products (which causes pinching and damage), the invention uses a horizontal barrier that moves laterally into the product path. This inverted approach achieves the same flow control function without the harmful downward motion that causes injury and damage
Solution Approach 2:
The retractable barrier serves as a safe intermediary device that controls product flow without directly contacting or pinching products. Unlike vertical gates that crush products between moving parts, this barrier gently blocks product advancement through lateral movement, eliminating the harmful effects while maintaining flow control
3Reliability
If the take-away table is stopped or slowed, then product loss during transfer is reduced, but improper product placement and faulty transfer occur
Solution Approach 1:
The retractable barrier acts as a mediator that enables precise product placement during transfer by controlling the timing and position of product flow without disrupting the conveyor's motion. This allows products to be positioned accurately on the stack while the conveyor maintains its speed and rhythm
Solution Approach 2:
The barrier is extended in advance before product transfer begins, preparing the system to capture products at the correct position. This preliminary action ensures that products are properly positioned on the stack before transfer completes, maintaining placement accuracy without requiring conveyor speed reduction
Data Source
AI summary
Pressware stacking systems and methods for using same. The system can include a conveyor for moving pressware in a first direction; a stop ramp at least partially disposed on the conveyor; and a lifter in communication with the stop ramp. The lifter is adapted to move at least a portion of the stop ramp to an inclined position above the conveyor.