Servo Flight Stacking for Packing Flexible-Sided Products
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing packaging techniques fail to effectively group and package products such as food items in flexibly-sided containers, like powdered gravy mix, due to complex design requirements.
Innovation Solution
A product-stacking and case-packing system utilizing a product-stacking assembly with servo motor-driven flights to down-stack incoming products and a robotic arm with end-of-arm tool to grasp and pack groups of products into cases, allowing simultaneous down-stacking and case-packing operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional packaging techniques are used, then the packaging process is simple, but the system cannot satisfy complex design requirements for grouping and packaging flexibly-sided products
Solution Approach 1:
The packaging system is divided into distinct functional modules: a product-stacking assembly with multiple flight assemblies for receiving and stacking products, and a separate case-packing assembly with robotic arms for packing. This segmentation allows each module to be optimized independently for its specific function while working together to handle complex packaging requirements.
Solution Approach 2:
The patent introduces an intermediary product-stacking assembly that receives products from the conveyor, stacks them into groups, and then transfers them to the case-packing assembly. This intermediary component bridges the gap between simple product transport and complex case packing, enabling the system to handle flexibly-sided products effectively.
2Productivity
If manual packaging operations are used, then the system is simple to operate, but productivity is low
Solution Approach 1:
The system employs robotic arms with end-of-arm tools that automatically grasp stacked products and place them into cases without human intervention. The flight assemblies automatically index and present products, and the robotic system self-regulates the packing process, eliminating the need for manual operations while maintaining high productivity.
Solution Approach 2:
Manual packaging operations are replaced with an automated robotic system that uses computer-controlled robotic arms to perform grasping and packing tasks. This substitution of mechanical automation for manual labor dramatically increases packaging throughput while reducing operational complexity through centralized control.
3Productivity
If products are streamed down a conveyor belt continuously, then the input flow is maintained, but the products cannot be effectively grouped and packaged
Solution Approach 1:
The flight assemblies operate with periodic indexing motion, stopping at predetermined positions to receive products from the conveyor and then moving to transfer positions. This periodic action allows the system to maintain continuous product input flow while accurately grouping products by pausing at specific intervals to stack items into complete groups before transferring to the case-packing assembly.
Data Source
AI summary
Techniques for product-stacking and case-packing are particularly adapted for product that is packaged in envelopes or flexibly-sided containers. Such products include may different types, such as foodstuffs, books, boxed goods, etc. In an example, a product-stacking and case-packing system may include a product-stacking assembly and a case-packing assembly. In the example, the product-stacking assembly may be configured with a plurality of pairs of flights, each pair of flights programmed to move according to operation of an associated pair servo motors, and programmed to receive and down-stack incoming product items into groups. In the example, the case-packing assembly may include a robotic arm and end-of-arm tool configured to grasp one or more groups of stacked product items, when pushed from the product-stacking assembly, and place each group of stacked product items in a case (e.g., a cardboard box).