Rotating Disc Card Assembly for Automated Single-Dose Vial Insertion
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Solution Overview
Problem
Current systems lack an automated solution for assembling cards with single-dose vials, which involves high labor costs and time when large quantities are needed, as they require manual handling of card shaping, folding, vial insertion, and packaging.
Innovation Solution
A machine with a rotating disc system and synchronized punch mechanism for automated card shaping, folding, die-cutting, and vial insertion, using interchangeable components to adapt to different card models, ensuring efficient assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual handling is used for card shaping, folding, and vial insertion, then labor flexibility is maintained, but labor costs and assembly time increase significantly
Solution Approach 1:
The machine is divided into distinct functional modules: a rotating disc with multiple housings for card shaping, a separate punch mechanism for folding and die-cutting, and an independent vial insertion unit. Each module performs a specific task in the assembly sequence, allowing automated high-speed production while maintaining manageable system complexity through functional decomposition.
Solution Approach 2:
The rotating disc system with multiple housings serves multiple functions: it holds cards during shaping, positions them for folding, and facilitates vial insertion. The punch mechanism performs both folding and die-cutting operations. This multi-functionality increases productivity by consolidating operations into a single automated machine while the modular design keeps the overall system complexity controlled.
2Productivity
If automated assembly is implemented, then labor costs and assembly time are reduced, but the machine must handle variable card formats
Solution Approach 1:
The machine incorporates adjustable and interchangeable components that can be dynamically reconfigured for different card formats. The rotating disc housings and punch mechanisms can be adjusted to accommodate variable card dimensions and folding patterns, allowing the automated system to maintain high throughput while adapting to different product specifications.
3Extent of automation
If a rotating disc system with multiple housings is used, then assembly operations are synchronized and automated, but the device complexity increases
Solution Approach 1:
The patent merges multiple assembly operations (card shaping, folding, die-cutting, and vial insertion) into a single rotating disc system where all operations are synchronized through the disc's rotation. This consolidation achieves high-level automation by coordinating all functions in one integrated mechanism, while the modular housing design keeps the complexity manageable by organizing functions into discrete, replaceable units.
Data Source
Figure 1-A~2
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Figure 5~6
AI summary
Machine for the automated supply of cards with single-dose vial comprising: a feeding station (4) of cards (2); a loading station (5) that picks up the cards (2) from the feeding station (4); a rotating disc (7), with housings (6) defining a shaping die, which rotates sequentially; a structure of various punches (8) associated with a lifting and lowering mechanism (10) configured with different ends (8a) for folding, marking fasteners or pushing the cards; and a vial (3) insertion unit (9) that inserts a vial (3) into the folded cards (2) inside the housing (6), all of them operated automatically and synchronously.