Rotating Pocket Wheels for Damage-Free Optical Test Object Separation
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Solution Overview
Problem
Existing separating devices for rotationally symmetrical test objects, such as container closures, face issues with damaging the test objects during separation, inaccurate positioning, and the inability to handle gaps in the transport flow without stopping the conveyor system, especially when the guarantee band is folded or the objects are not oriented correctly.
Innovation Solution
The use of two synchronously rotating pocket wheels with evenly distributed pockets along their circumference, which engage with the lateral surface of the test objects to separate them without damaging the sensitive upper edge, and a control system to adjust their rotational speed relative to the conveyor speed to maintain an undisturbed accumulation section and ensure correct spacing between objects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If fingers of a star wheel are used to separate test objects by penetrating into them, then separation can be achieved, but the test objects may be damaged and positioning becomes inaccurate
Solution Approach 1:
The patent introduces a buffer zone as an intermediary section between the star wheel separation point and the testing position. This buffer zone absorbs positioning errors and allows time for the star wheel to return to its original position, ensuring that subsequent test objects are correctly spaced without directly contacting the delicate test objects with high forces.
Solution Approach 2:
The buffer zone serves as a cushioning mechanism that pre-compensates for positioning inaccuracies and potential damage. By providing this protective zone beforehand, the system prevents the propagation of harmful effects from the separation process to the actual testing area.
2Productivity
If the star wheel rotates at high speed to maintain transport flow, then productivity is improved, but gaps in transport flow cannot be handled without stopping the system
Solution Approach 1:
The patent implements a movable star wheel that can dynamically adjust its position and rotational speed. The control system monitors the transport flow and adjusts the star wheel's operation in real-time, allowing it to slow down or pause when gaps are detected, and resume normal operation when flow is restored, without requiring complete system shutdown.
Solution Approach 2:
The system incorporates feedback control where the position and movement of test objects are continuously monitored. This feedback allows the control system to detect gaps in the transport flow and adjust the star wheel's operation accordingly, maintaining both high productivity and reliable gap handling.
3Ease of operation
If the star wheel fingers are positioned to engage test objects, then separation is achieved, but high forces are exerted when objects are incorrectly oriented
Solution Approach 1:
The buffer zone is positioned upstream of the testing area to preemptively absorb and mitigate the effects of high forces generated during separation. This preliminary protective measure prevents incorrectly oriented objects from reaching the testing position, where they could cause damage or inaccurate measurements.
Solution Approach 2:
The buffer zone acts as an intermediary between the high-force separation process and the sensitive testing area. It provides a transition region where incorrectly oriented objects can be identified and excluded before they interfere with the testing process.
4Productivity
If the star wheel returns to original position quickly, then productivity is maintained, but subsequent test objects are not spaced apart correctly
Solution Approach 1:
The buffer zone serves as a mediator that decouples the star wheel's return motion from the spacing of subsequent test objects. While the star wheel quickly returns to its original position to maintain productivity, the buffer zone ensures that test objects are correctly spaced before they reach the testing position, preserving manufacturing precision.
Solution Approach 2:
The system dynamically manages the star wheel's motion profile, allowing rapid return when needed while using the buffer zone to maintain proper spacing. This dynamic control enables the system to prioritize productivity without sacrificing spacing accuracy in the critical testing area.
Data Source
Figure 1A~1D
Figure 2
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AI summary
In order to create a separating device of an optical testing unit for rotationally symmetrical test objects where damage to test objects is largely avoided, it is proposed that, for separating purposes, two corresponding pocket wheels (3.1, 3.2) having a plurality of pockets (3.4) distributed uniformly over the circumference should be provided, said pocket wheels being made to rotate synchronously in opposite directions about parallel axes by means of a drive. Depending on the geometry of the test objects, the distances between the respective pocket wheels (3.1, 3.2) and between said pocket wheels and a transporting plane of a continuous conveyor are determined such that the test objects which are fed via an accumulating section (7) of the continuous conveyor are moved through between the pocket wheels (3.1, 3.2) while being guided in a form-fitting manner in each case by two pockets of the two pocket wheels (3.1, 3.2), and are released by the two pockets downstream of the engagement section (8). Once released, the test objects are accelerated to a higher transporting speed in an accelerating section (9) of the continuous conveyor and are separated as a result.