Stacking Device with Segmented Drive Units for Continuous Pouch Formation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing bag stacking devices face inefficiencies in forming continuous stacks with endless or severed bags, particularly in creating zigzag-shaped layers and maintaining consistent bag orientation, while also requiring manual intervention for stack transport and potential interruptions in the stacking process.
Innovation Solution
A stacking device with a first drive unit for stacking movement and a second drive unit for transport movement, utilizing a bag feed mechanism with a deflection device to bend and stack bags in a zigzag pattern, and a control unit to adjust stroke and speed based on stack height, allowing continuous and flexible formation of stacks with varying numbers of bags per layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single drive unit is used for both stacking movement and transport movement, then device complexity is reduced, but the stacking process may be interrupted when transport is required
Solution Approach 1:
The drive system is segmented into at least two independent drive units: a first drive unit dedicated to stacking movement and a second drive unit dedicated to transport movement. This segmentation allows each drive unit to operate independently, ensuring that transport operations do not interrupt the stacking process, thereby resolving the contradiction between device complexity and process continuity.
Solution Approach 2:
The patent combines the stacking function and transport function into a single integrated device with coordinated control. While the drive units are separate, their operations are merged through control unit coordination, allowing the device to perform both functions without requiring completely separate systems, thus balancing complexity and reliability.
2Productivity
If the stacking base moves continuously to form zigzag layers, then stacking speed increases, but bag orientation consistency becomes difficult to maintain
Solution Approach 1:
The stacking base employs dynamic movement with adjustable stroke and speed parameters controlled by a control unit. The system can adapt its motion characteristics in real-time to maintain bag orientation consistency while achieving high stacking speeds, resolving the contradiction between productivity and manufacturing precision.
Solution Approach 2:
The control unit monitors stacking parameters and adjusts the stacking base movement accordingly to maintain consistent bag orientation. Through feedback control, the system optimizes the stacking motion to preserve orientation consistency even at high speeds, addressing the contradiction between stacking speed and orientation precision.
3Device complexity
If manual intervention is used for stack transport, then device complexity is reduced, but productivity decreases due to interruptions
Solution Approach 1:
The device is equipped with an automated transport mechanism (stacking transport device) that autonomously transports formed stacks away from the stacking area. This self-service capability eliminates the need for manual intervention, preventing interruptions in the stacking process and maintaining high productivity, thus resolving the contradiction between device complexity and productivity.
4Device complexity
If the stacking base stroke is fixed, then device complexity is reduced, but adaptability to different stack heights is limited
Solution Approach 1:
The stacking base stroke is made dynamically adjustable through control unit regulation. The system can modify stroke length and movement speed according to different stacking requirements, enabling adaptability to various stack heights while maintaining reasonable control system complexity through parameter-based adjustment rather than mechanical reconfiguration.
Solution Approach 2:
The control unit enables parameter changes in the stacking base movement, including stroke length and speed, to adapt to different stacking scenarios. By changing operational parameters rather than physical structure, the system achieves versatility in handling different stack heights without significantly increasing device complexity.
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
The invention relates to a stacking device for continuously forming stacks (12a-e) of bags (18a), which bags are continuously fed in at least one bag strand (16a,d-e), which comprises at least one bag row (14a) and which is endless or cut through after each series of a defined number of bags, the stacking device comprising: at least one stack base (24a-e, 24'a-b), which is moved back and forth in a stacking motion (22a-e, 22'a) parallel to a stack layer direction (20a) at least during the formation of a stack (12a-e); a bag-feeding means (26a-d), which lays the at least one bag strand (16a,d-e) on the stack base (24a-e, 24'a-b) in such a way that the bag strand (16a,d-e) bends at least substantially because of the stacking motion (22a-e, 22'a) after each series of a number of bags that forms a stack layer (28a,c-d) and forms zig-zag-shaped stack layers (28a,c-d) or that the bag strand (16a,d-e) is layered at least substantially because of the stacking motion (22a-e, 22'a) with matching bag orientation into stack layers (28a,c-d) having the number of bags that forms the stack layer (28a,c-d); and at least one stack-transporting means (30a-e, 30'a-b) for transporting the stacks (12a-e) out of the region of influence of the stacking motion (22a-e, 22'a) after a specified number of stack layers has been reached. According to the invention a first driving unit (32a-e, 32'a-b) for driving at least one stacking motion (22a-e) is provided and a further driving unit (32'a-e, 32a-b) for driving at least one transporting motion (34a-e, 34'a) of at least one stack-transporting means (30a-e, 30'a-b) is provided.