Roll Product Batch Forming Machine with Movable Dividing Means
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Solution Overview
Problem
Current production machines for rolls of products are inflexible and costly to reconfigure for producing both packaged and loose batches, as they are designed for a single type of product output, making changes to meet manufacturer requirements complex and expensive.
Innovation Solution
A machine with a first unit for transporting groups of products and a second unit for grouping, along with a work surface for batch selection and forming, controlled by a programmable unit to form batches suitable for either packaging or palletizing, allowing for flexible operation and configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the machine is designed for a single type of product output (packaged or loose batches), then the production process is simplified and reliable, but the adaptability to meet different manufacturer requirements is reduced
Solution Approach 1:
The machine is designed with a universal architecture that can handle both packaged batches (with outer packaging) and loose batches (for palletizing) through the same production line. The end of line unit includes a work surface with movable dividing means that can be configured to either package batches or divert them for loose handling, eliminating the need for separate production lines for different product types.
Solution Approach 2:
The end of line unit incorporates dynamically adjustable components, including movable dividing means on the work surface that can be repositioned based on production requirements. This dynamic configuration allows the same machine to adapt between packaged and loose batch production modes by adjusting the position and configuration of dividing elements, rather than requiring static, fixed configurations.
2Adaptability or versatility
If the machine is reconfigured to produce both packaged and loose batches, then the adaptability is improved, but the device complexity and reconfiguration cost increase
Solution Approach 1:
The end of line unit is designed as a universal system that can perform both packaging operations and loose batch handling through a single integrated structure. The work surface with movable dividing means serves dual purposes: creating packaged batches when configured one way, and directing loose batches for palletizing when configured another way, thereby reducing overall system complexity.
Solution Approach 2:
The end of line unit is segmented into functional zones with movable dividing means that can be independently positioned. This segmentation allows the system to create different batch configurations without requiring complete system redesign. The dividing means can be moved to create packages or to direct loose batches, providing flexibility without proportionally increasing complexity.
3Adaptability or versatility
If the bagging unit is left non-operational when producing loose batches, then the machine can meet diverse requirements, but the productivity is reduced due to unused capacity
Solution Approach 1:
The system dynamically reconfigures the end of line unit based on production requirements. When loose batches are being produced, the movable dividing means are repositioned to divert batches away from the bagging unit, allowing the bagging unit to be disabled without interrupting the main production flow. This dynamic reconfiguration maintains productivity by ensuring continuous operation of the active production path.
Solution Approach 2:
The machine is pre-configured with movable dividing means and control systems that can preemptively redirect batches before they reach the bagging unit. This preliminary action allows the system to prepare for loose batch production by positioning dividing elements in advance, ensuring smooth transition and maintaining productivity without sudden interruptions or idle capacity.
Data Source
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AI summary
A machine for the production of groups (1) of rolls of products, each group consisting of a plurality of products (2) grouped together to constitute a format and wrapped and closed in a sheet of film. Along a feed line (A) the machine (3) comprises: a first unit (4) for transporting the groups (1) of products one after another towards a second unit (5) for picking up and grouping a plurality of groups (1) of products; a first work surface (6) with batch (L1; L2) selection and forming means (7); a programmable control unit (18) controlling the selection and forming means (7) and the second unit (5), and designed to allow, immediately downstream of the second unit (5), relative to the feed line (A), formation of the batches (L1; L2) of products depending on their type of destination downstream of the second unit (5).