Segmented Vacuum Pallet Carousel for Label Transfer
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Solution Overview
Problem
Current pallet carousels face inefficiencies in label removal from the label magazine during startup and shutdown, and the intake of external air reduces vacuum pressure, leading to potential removal errors and increased operational costs due to the need for powerful vacuum supplies.
Innovation Solution
A pallet carousel with a segmented vacuum channel and individually controllable valves allows for targeted vacuum supply to each vacuum pallet, preventing external air intake and optimizing label removal by selectively switching vacuum on or off based on the presence of labels, and using compressed air for label ejection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the label magazine is moved away from the pallet carousel to prevent label removal during startup and shutdown, then label removal errors are prevented, but the transport speed must be reduced due to the mass inertia of the label magazine
Solution Approach 1:
The vacuum channel is divided into multiple segments, each with individually controllable valves. This allows selective activation of vacuum in specific segments corresponding to different pallet positions, enabling precise control of label removal operations without moving the entire label magazine or affecting other parts of the system.
Solution Approach 2:
The system dynamically controls vacuum application to individual pallets based on their position and operational state. During startup and shutdown, vacuum is selectively deactivated for pallets that should not remove labels, while maintaining vacuum for other pallets, allowing the label magazine to remain in position while preventing unwanted label removal.
2Device complexity
If a common vacuum supply is used for all pallets, then the system structure is simple, but empty pallets suck in external air which reduces negative pressure and causes removal errors
Solution Approach 1:
The common vacuum supply is segmented into multiple independently controllable sections. Each segment has its own valve that can be opened or closed based on the operational needs of corresponding pallets. This maintains structural simplicity while preventing external air intake by isolating segments with empty pallets from the vacuum supply.
Solution Approach 2:
Different segments of the vacuum channel have different vacuum states controlled by local valves. Segments corresponding to loaded pallets maintain negative pressure for label removal, while segments corresponding to empty pallets are isolated to prevent external air intake, creating locally optimized conditions for each pallet's state.
3Reliability
If the central vacuum supply is made powerful enough to compensate for external air intake from empty pallets, then label removal reliability is maintained, but construction and operation costs increase
Solution Approach 1:
The vacuum supply system is segmented so that vacuum is applied only to segments containing loaded pallets that need label removal. Segments with empty pallets are isolated using valves, eliminating the need to compensate for their external air intake. This reduces the required vacuum supply power while maintaining label removal reliability.
Solution Approach 2:
Instead of applying vacuum to all pallets uniformly (excessive action), the system applies vacuum only where needed (partial action). By selectively activating vacuum segments based on pallet content, the system avoids the energy waste of maintaining vacuum for empty pallets while ensuring reliable label removal from loaded pallets.
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 ensures reliable and efficient label removal with reduced external air intake, minimizing errors and operational costs by adapting vacuum supply to the specific needs of each pallet, maintaining continuous vacuum and preventing unwanted label picking during machine startup and shutdown.
Implementation Method 1
a central vacuum supply (16) which can be connected by means of a vacuum channel (7) to several vacuum connections (9) circulating along an orbit (6) for individually assigned vacuum pallets (10)
Implementation Method 2
a compressed air supply (20), which is arranged on the stationary machine part in an angular machine area not covered by the vacuum channel (7) and is temporarily swept over by the vacuum connections (9) circulating on the rotor (8) in order to apply overpressure to the associated vacuum pallets (10) to eject the labels
Data Source
Figure 1
Figure 2
Figure 3A
AI summary
A pallet carousel (1) for removing labels (2) from a label magazine (3) and transferring the labels to containers (4) is described, as well as a corresponding method for suctioning the labels onto the pallet carousel. The pallet carousel comprises a stationary machine part (5) with a central vacuum supply and a vacuum channel (7) connected to it and running along a circular track. Furthermore, the pallet carousel includes a rotor (8) that seals against the vacuum channel and has vacuum connections (9) distributed along the circular track. These connections are linked to individual vacuum pallets (10) stored on the carousel and connect them to the vacuum channel as the rotor passes over it.Because the vacuum channel along the orbit is divided into several separate segments and these are connected to the vacuum supply via individually controllable valves, the vacuum supply to individual vacuum pallets can be selectively shut off if they are not to receive a label from the label magazine and/or are not equipped with a label.