Rusk Grouping Unit Using Vibrating Chutes and U-Shaped Pockets
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Solution Overview
Problem
Existing methods for forming groups of rusks or similar baked products are inefficient in handling fragile products at high speeds, often resulting in breakage and require additional orienting devices to manage product orientation, which can bottleneck the production process.
Innovation Solution
A method and unit that uses vibrating chutes to upend rusks into compact groups, forming them within U-shaped pockets and transferring them to a conveyor using a transfer device that rotates the groups gently into position, ensuring they are aligned correctly for packaging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If products are released onto the conveyor by opening pockets at high speed, then productivity increases, but product breakage increases
Solution Approach 1:
The patent applies beforehand cushioning by having products rest on a cushioning surface (conveyor belt or cushioning element) before being transferred into the pocket. This pre-positioning on a compliant surface reduces impact forces during the subsequent release, allowing high-speed operation without causing product breakage.
Solution Approach 2:
The patent introduces an intermediary cushioning surface between the pocket release mechanism and the final product destination. This intermediary element absorbs and dissipates impact energy, mediating the transfer of products from the pocket to the conveyor without direct hard impact, thus preventing breakage while maintaining high productivity.
2Device complexity
If products are transferred with the same orientation as inserted into pockets, then device complexity is reduced, but additional orienting devices are required downstream
Solution Approach 1:
The patent merges the orientation function into the pocket structure itself. The pockets are designed with a specific geometry and mounting orientation that automatically orients products in the desired configuration during the grouping process, eliminating the need for separate downstream orienting devices and maintaining high productivity.
Solution Approach 2:
The patent performs preliminary orientation action during the product insertion phase. Products are oriented correctly as they are fed into the pockets, rather than requiring re-orientation later in the process. This preliminary action simplifies the overall system and maintains packaging output rate by avoiding downstream bottlenecks.
3Object-affected harmful factors
If products are handled gently to prevent breakage, then product integrity is maintained, but processing speed must be reduced
Solution Approach 1:
The patent uses beforehand cushioning to enable gentle product handling even at high processing speeds. The cushioning surface is positioned in advance to catch and support products during transfer, allowing the system to operate quickly while maintaining low impact forces that prevent product breakage.
Solution Approach 2:
The patent employs dynamic elements such as movable pockets, adjustable cushioning surfaces, or spring-loaded mechanisms that adapt to product characteristics and movement speeds. This dynamic adjustment allows the system to maintain gentle handling conditions across a range of processing speeds, preventing breakage while maximizing productivity.
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 approach reduces breakage and eliminates the need for separate orienting devices, enhancing the efficiency and reliability of the packaging process by handling fragile products with care and maintaining product orientation during high-speed processing.
Implementation Method 1
vibrating chutes to upend rusks into compact groups
Data Source
Figure 1
Figure 2~5
Figure 3
AI summary
In a unit (1) for forming groups (2) of rusks (3) or similar products, a given number of lines (6) of rusks (3) are fed to respective pockets (22) in a feed direction (9), each line (6) being defined by a succession of rusks (3) positioned in a first orientation and packed together in a compact configuration in the feed direction (9); each line (6) is arrested when a given number of rusks (3) has been fed into the relative pocket (22) to form a respective group (2) inside the pocket (22); each group (2) is extracted from the respective pocket (22) by means of a respective gripper (39), which is moved to an output station (7) and opened to release the respective group (2) onto an output conveyor (15).