Rotating Bucket Conveyor for Vertical Item Loading
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Solution Overview
Problem
Existing cartoning systems face challenges in efficiently loading items vertically, as vertical cartoners require complex equipment and horizontal cartoners struggle with horizontal loading of certain items, limiting their application and efficiency.
Innovation Solution
A conveyor system with rotating buckets that change orientation from horizontal to vertical, allowing for vertical loading of items by rotating the buckets around an axis inclined at an acute angle, enabling the use of horizontal cartons for vertical item placement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a vertical cartoner is used to load items vertically into cartons, then the loading efficiency and gravity utilization are improved, but the equipment complexity increases
Solution Approach 1:
The patent applies dynamics by making the conveyor system rotatable, allowing it to change orientation between horizontal and vertical positions. The conveyor can rotate to orient cartons vertically during loading, then return to horizontal for discharge, enabling a single system to perform both horizontal and vertical loading functions dynamically
Solution Approach 2:
The patent implements universality by designing a single conveyor system that can perform multiple functions: horizontal transport, vertical loading, and discharge operations. By rotating the conveyor to different orientations, the same equipment handles both horizontal cartoning and vertical loading tasks that would traditionally require separate machines
2Device complexity
If a horizontal cartoner is used to simplify equipment construction, then the device complexity is reduced, but the ability to vertically load certain items is lost
Solution Approach 1:
The conveyor system is made rotatable about its axis, allowing it to dynamically change orientation. This enables the system to present cartons horizontally for easy loading of certain items, then rotate to vertical orientation for loading items that require vertical placement, and finally return to horizontal for discharge
Solution Approach 2:
The patent adds rotational movement as another dimension of motion to the conventional linear conveyor system. By introducing rotation about the conveyor axis, the system can transition between horizontal and vertical orientations, adding versatility without fundamentally changing the basic conveyor structure
3Adaptability or versatility
If a rotatable conveyor is used to enable both horizontal and vertical loading, then the adaptability is improved, but the device complexity increases
Solution Approach 1:
The rotatable conveyor serves multiple functions: horizontal transport, vertical loading, and discharge. By making the conveyor itself rotatable rather than adding separate mechanisms for each function, the patent achieves multi-functionality with a single integrated system
Solution Approach 2:
The patent merges the loading and discharge functions into a single conveyor system that can orient itself appropriately. Instead of having separate loading mechanisms and discharge mechanisms, the rotatable conveyor handles both operations by changing its orientation, combining multiple functions into one device
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution enhances the efficiency and cost-effectiveness of item loading by allowing vertical loading in a horizontal carton format, improving throughput and reducing the need for complex equipment, while accommodating items that require vertical orientation.
Implementation Method 1
the conveyor being configured and operable to rotate each of the plurality of buckets in series around the axis of rotation from the first path portion to the second path portion; wherein the at least one inner surface of the container is oriented generally in or parallel to the horizontal plane when the buckets are moved along the first path portion and wherein the at least one inner surface is oriented at an angle to the horizontal plane
Data Source
AI summary
A system is disclosed for loading at least one item into each of a plurality of containers. The system includes a plurality of buckets, each configured for supporting at least one container. The system also has a conveyor interconnected to each of the buckets. The conveyor has a conveyor axis of rotation that is oriented at an acute conveyor angle to a horizontal plane. The buckets are oriented relative to the conveyor axis of rotation by a wedge angle. The buckets move in series around the axis of rotation from a first path portion to a second path portion. An inner surface of the container is oriented generally in or parallel to the horizontal plane when the buckets are moved along the first path portion and the inner surface is oriented at an angle to the horizontal plane that is of an amount that is twice the wedge angle when the buckets are moved along the second path portion.