Sanitary Article Packaging Diverter for Mixed-Size Production
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Sanitary product packaging lines face challenges in efficiently handling high production rates and varying package sizes, requiring different packaging configurations without the need for multiple production lines, while also accommodating niche market demands and morphological variations.
Innovation Solution
A method and system utilizing a diverter device to selectively deflect sanitary articles into two flows, one for large packages and another for small packages, with dynamic control to adjust the number of articles in small packages, allowing for flexible packaging configurations and accommodating different morphologies and market demands.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single production line is used to package both large and small packages, then device complexity is reduced, but manufacturing precision deteriorates due to the difficulty of accommodating different package configurations and article counts
Solution Approach 1:
The patent employs dynamic control systems including variable speed conveyors, adjustable diverters, and programmable logic controllers that can adapt in real-time to different packaging requirements. The system dynamically adjusts article routing, grouping, and packaging parameters based on the selected package type, enabling a single line to precisely handle both large multi-article packages and small single-article packages without compromising accuracy
Solution Approach 2:
The system changes operational parameters such as conveyor speed, diverter activation timing, article grouping counts, and packaging machine settings based on the desired package configuration. By programmatically adjusting these parameters, the single production line can switch between different package types (e.g., 1-5 articles per package) while maintaining precise packaging accuracy for each configuration
2Productivity
If production rate is increased to 1000 articles per minute, then productivity is improved, but measurement precision deteriorates as individual articles can no longer be distinguished
Solution Approach 1:
The patent replaces mechanical/optical detection systems with electronic sensing and control systems including capacitive sensors, inductive sensors, and RFID readers that can detect and count articles at high speeds. These electronic systems process signals at frequencies much higher than human visual perception, enabling precise article identification and counting even at 1000 articles per minute production rates
Solution Approach 2:
The system introduces intermediary components such as article guides, positioning mechanisms, and buffering zones that slow down or space out articles temporarily during critical detection and routing points. This allows sensors and control systems to accurately distinguish and process each article individually even when the overall production line operates at very high speeds, effectively decoupling production rate from measurement precision requirements
3Manufacturing precision
If multiple production lines are used to handle different package sizes, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The patent designs a universal production line with multi-functional capabilities that can handle various package types through programmable control. The system includes adjustable diverters, variable-speed conveyors, and reconfigurable packaging stations that can be programmed to create different package configurations (single articles, multi-article packages, various pack sizes) without requiring physical reconfiguration or separate production lines, thus achieving precision for all package types on a single line
4Device complexity
If a fixed packaging configuration is used, then device complexity is reduced, but adaptability deteriorates due to inability to meet different market requirements
Solution Approach 1:
The patent implements dynamic control systems with programmable logic controllers and variable speed drives that allow the packaging line to adapt to different package configurations on-demand. The system can switch between package types (different article counts, package sizes, and morphologies) by changing control parameters rather than physical configuration, maintaining low device complexity while achieving high adaptability to meet diverse market requirements
Solution Approach 2:
The system achieves adaptability through parameter changes including adjustable diverter activation points, variable conveyor speeds, programmable article grouping counts, and flexible packaging machine settings. These parameters can be modified via software control to accommodate different market demands (travel packages, home use packages, niche market packages) without requiring complex physical reconfiguration of the production line
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A method for automatic packaging of sanitary articles (A) in at least one first type of package (I) and one second type of package (II) containing, respectively, a first number of articles and a second number of articles, envisages: - providing a flow of incoming articles (A); - diverting (10) articles from said flow of articles with a ratio between non-deflected articles and deflected articles that is a function of the ratio between the aforesaid first number and the aforesaid second number, generating a main flow of non-deflected articles (A) that may be packaged in the packages of the first type (I) and a derived flow of deflected articles that may be packaged in the packages of the second type (II).