Roll Sorter Device for Preform Alignment and Seized Part Removal
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Solution Overview
Problem
Existing roll sorter devices are unable to effectively remove seized preforms from their rolls, which hinders the sorting and alignment process of plastic preforms in the manufacturing of containers.
Innovation Solution
A roll sorter device with a detection system and a roll arrangement modification element that adjusts the position and spacing of the rolls to detect and eject seized preforms, allowing for automatic alignment and sorting of preforms by modifying the roll arrangement through motorized or pneumatic means, such as shifting, swiveling, or changing the distance between the rolls.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a fixed roll sorter device is used to align preforms, then preforms can be sorted in a predetermined direction, but seized preforms cannot be removed from the rolls
Solution Approach 1:
The roll sorter device incorporates movable rolls that can be shifted relative to each other in the rolling direction. The detection device identifies seized preforms, and the roll arrangement modification element adjusts the position of at least one roll dynamically to create spacing that enables removal of seized preforms, transforming a static system into an adaptive one.
Solution Approach 2:
The detection device continuously monitors the rolls for seized preforms and provides feedback to the roll arrangement modification element. When seized preforms are detected, the system automatically adjusts the roll arrangement to remove them, creating a closed-loop control system that responds to actual operating conditions.
2Manufacturing precision
If the roll gap is made smaller to improve sorting precision, then preform alignment improves, but seized preforms become more difficult to remove
Solution Approach 1:
The system maintains a small roll gap for precise alignment during normal operation, but dynamically increases the gap when seized preforms are detected. The roll arrangement modification element shifts at least one roll to create sufficient spacing for removing seized preforms, then returns to the precise alignment configuration afterward.
Solution Approach 2:
The roll gap parameter is dynamically adjusted based on detection device feedback. During normal sorting, the gap maintains precise alignment; when seized preforms are detected, the gap parameter changes to allow removal, resolving the contradiction between precision and removability.
3Reliability
If a detection device is added to identify seized preforms, then seized preform detection improves, but device complexity increases
Solution Approach 1:
The detection device replaces complex manual inspection mechanisms with automated sensing technology. Optical sensors or other detection devices identify seized preforms automatically, eliminating the need for complex mechanical inspection systems while maintaining high detection accuracy.
Solution Approach 2:
The system uses the detection device to automatically identify and trigger removal of seized preforms without human intervention. The roll arrangement modification element responds autonomously to detection device signals, creating a self-managing system that reduces operational complexity.
Data Source
AI summary
A roll sorter device has a first roll that can be driven rotatably about its roll axis and a second roll that can be driven rotatably about its roll axis opposite the rotation of the first roll. The second roll is arranged spaced from the first roll such that the roll axes of the first and second rolls are arranged substantially parallel to each other. The roll sorter device may include a detection device for detecting seized and/or faulty preforms on the first or second roll and a roll arrangement modification element to modify the arrangement of the first and second rolls to each other when the detection device detects seized preforms. A sorting method for sorting performs and a transport device may employ the aforementioned roll sorter device.