Singulation Rotary Head with Light Barrier Detection
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Solution Overview
Problem
Existing devices and methods for packaging small-sized products, such as bouillon cubes and confectionery, fail to effectively reject defective or incorrectly positioned products, leading to product destruction, machine contamination, and increased cleaning requirements, and are complex and costly due to the need for multiple belts and energy-intensive designs.
Innovation Solution
A method and device that utilize a single detection device, such as a light barrier, to immediately detect products after separation, allowing for early rejection of defective or mispositioned products before they enter the packaging process, and employing a rotary head with pivoting separating elements for synchronized and gentle product separation in parallel streams, reducing the risk of damage and contamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple belts and complex synchronization mechanisms are used for product separation, then product positioning precision is improved, but device complexity and energy consumption increase
Solution Approach 1:
The patent extracts and eliminates the complex multi-belt synchronization mechanisms from the system. Instead of using multiple belts working together, the invention uses a single belt with a simple pickup station that grabs products one at a time, removing unnecessary complexity while maintaining separation precision.
Solution Approach 2:
The patent replaces complex mechanical synchronization systems with a sensor-based detection and control system. Optical sensors detect product positions and trigger the pickup mechanism, substituting mechanical complexity with electronic sensing and control.
2Manufacturing precision
If multiple belts and vacuum-supported acceleration belts are used for product synchronization, then product separation accuracy is improved, but energy consumption increases
Solution Approach 1:
The patent removes the vacuum-supported acceleration belt from the system. The single belt operates at constant speed, and products are picked up individually without requiring additional vacuum acceleration, thereby eliminating the extra energy consumption associated with vacuum systems.
Solution Approach 2:
The system uses the natural flow of products on the single belt and simple gravitational feeding into the pickup station. Products are separated through the timing and positioning of the pickup mechanism itself, without requiring additional energy-intensive acceleration or synchronization belts.
3Productivity
If defective products are forced into the packaging process without rejection capability, then productivity is maintained, but product quality and process reliability deteriorate
Solution Approach 1:
The patent implements preliminary detection and rejection of defective products before they enter the packaging process. Sensors detect positioning errors or defects, and the system rejects these products in advance, preventing them from disrupting downstream packaging operations.
Solution Approach 2:
The system uses optical sensors to continuously monitor product positioning and provides feedback to the control system. When defects or mispositioning are detected, the feedback triggers automatic rejection, creating a closed-loop quality control system that maintains both productivity and reliability.
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
Significantly reduces the likelihood of mispositioned and damaged products entering the packaging process, minimizing machine contamination and cleaning requirements, while simplifying the design and reducing costs by using a single sensor and eliminating the need for complex belt systems.
Implementation Method 1
each isolated product is detected immediately after its separation by means of a detection device
Data Source
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AI summary
The present invention relates to a device and a method for singulating and processing small products, particularly in a packaging process in which the products are individually packaged. To avoid disruptions in the packaging process, the method according to the invention comprises the following steps: a. Step A: Feeding the products (P) in at least one product stream (PS) to a singulation station; b. Step B: Singulating the fed products (P) from the product stream (PS) in the singulation station; c. Step C: Detecting each singulated product (P) immediately after singulation by means of a detection device (S); d. Step D: Further processing or rejection of the products (P) based on the detection in step C. Furthermore, the invention provides a corresponding device.