Stacking Device with Dual Deposition Stations
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Solution Overview
Problem
Existing stacking devices for paper products like tissues and napkins require multiple star conveyors to increase production rate, leading to complex designs, high costs, and frequent downtime, as single conveyors cannot operate efficiently beyond a certain speed limit.
Innovation Solution
A stacking device with a single transfer star conveyor utilizing a wheel with tangential receptacles, dual deposition stations, and movable supporting surfaces with stop elements and actuation means to efficiently form and transfer stacks, allowing for higher production rates without complex designs or high costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single star conveyor is used, then device complexity is reduced, but production rate decreases due to speed limits and periodic inactivity
Solution Approach 1:
The single star conveyor is segmented into two independent working zones: a first deposition station with a first movable supporting surface and a second deposition station with a second movable supporting surface. Each station operates independently to form separate stacks, allowing the conveyor to serve two functions simultaneously and double the production rate without increasing the number of conveyors
Solution Approach 2:
The single star conveyor is designed to perform multiple functions by serving two deposition stations. The conveyor alternates between depositing products at the first station and the second station, making one conveyor unit universal for dual purposes, thereby maintaining simplicity while increasing productivity
2Productivity
If multiple star conveyors are used to increase production rate, then productivity increases, but device complexity and cost increase
Solution Approach 1:
Instead of using multiple complete conveyor systems, the invention segments a single conveyor into two functional zones with separate deposition stations. Each station has its own movable supporting surface and stop elements, creating independent working areas that operate in alternation, achieving multi-conveyor productivity with single-conveyor simplicity
Solution Approach 2:
The invention merges the functions of two separate conveyors into one unified system. By combining two deposition stations on a single star conveyor and coordinating their operation through alternating cycles, the system achieves the productivity of multiple conveyors while maintaining the simplicity and lower cost of a single conveyor unit
Data Source
AI summary
A stacking device for sheet products, comprising at least one wheel associated with rotary actuation means that has at least one plurality of tangential peripheral receptacles for accommodating already-folded products fed by a conveyor to at least one pick-up station, at least one first product deposition station, provided with a first fixed stop element for engaging the products accommodated in the receptacles and with a first movable supporting surface for picking up a first stack of products extracted from the receptacles, and at least one second product deposition station, which is provided with a second upper stop element and a second lower stop element, movable in opposition and both suitable to engage products accommodated in the receptacles, and with a second movable supporting surface suitable to pick up a second stack of products extracted from the receptacles.