Star Wheel Vacuum Plenum for Irregular Articles
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Solution Overview
Problem
Existing star wheels used in manufacturing processes for conveying articles, such as metal container bodies, face inefficiencies due to high energy costs and wear caused by the need for strong vacuum seals to counteract gravity and centrifugal forces, especially when handling irregularly shaped items.
Innovation Solution
A star wheel design featuring a hub with a rim and sidewalls that create a plenum with controlled vacuum openings, using low vacuum and high airflow to securely hold articles, reducing friction and wear by minimizing vacuum loss through a blocking surface that partially blocks airflow, allowing for efficient transport of irregularly shaped items.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a spring forces the valve against the wheel to maintain vacuum seal, then the vacuum seal is improved, but friction and wear increase and energy costs increase
Solution Approach 1:
The invention extracts the spring force mechanism from the system by using a stationary plenum that maintains vacuum without mechanical contact. The vacuum is generated and maintained in a stationary chamber, eliminating the need for springs to press valves against rotating wheels, thereby removing the source of friction and energy loss while preserving the vacuum seal function.
Solution Approach 2:
The stationary plenum acts as an intermediary between the vacuum source and the rotating wheel. Instead of directly applying vacuum through contact mechanisms (springs and valves), the plenum serves as a stationary intermediary chamber that distributes vacuum to the wheel through non-contact means, reducing mechanical friction and energy consumption.
2Reliability
If a spring forces the valve against the wheel to maintain vacuum seal, then the vacuum seal is improved, but friction and wear increase
Solution Approach 1:
The invention removes the spring force mechanism that causes wear. By using a stationary plenum to generate and maintain vacuum without mechanical contact with the rotating wheel, the system eliminates the continuous friction between springs and valves, thereby preventing wear and extending the operational lifespan of stationary components.
Solution Approach 2:
The invention replaces the mechanical spring- valve system with a stationary plenum-based vacuum generation system. This substitution eliminates the need for mechanical contact and friction between moving and stationary parts, thereby preventing wear while maintaining the vacuum seal necessary for reliable operation.
3Reliability
If high vacuum is applied to hold articles firmly in pockets, then article retention is improved, but energy consumption increases
Solution Approach 1:
The invention applies vacuum locally at the interface between the article and the pocket bottom rather than applying high vacuum throughout the entire pocket. The stationary plenum creates a localized vacuum zone that is sufficient to hold articles firmly during rotation, reducing overall energy consumption while maintaining reliable article retention where it is most needed.
Solution Approach 2:
The invention uses partial vacuum action rather than excessive vacuum. The stationary plenum generates just enough vacuum to securely hold articles in the pockets during rotation, avoiding the energy waste of applying excessive vacuum pressure throughout the entire pocket volume, thereby reducing energy consumption while maintaining adequate article retention.
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
The design enables cost-effective operation with reduced energy consumption and improved ability to hold irregularly shaped articles, minimizing article loss and wear, while maintaining secure retention during rotation.
Implementation Method 1
a vacuum system to hold the articles temporarily in place by means of negative air pressure generated between the article and the surrounding surface of the pocket
Implementation Method 2
A blocking surface is provided within the plenum positioned adjacent to, but out of contact with, the inner surface of the rim. The blocking surface partially blocks at least one but not all of the openings at the inner surface of said rim
Data Source
AI summary
The invention relates to a star wheel used for transporting articles in an arcuate path. The star wheel is provided with a vacuum apparatus to retain the articles within pockets of the star wheel as the wheel is rotated between a point where the articles are loaded onto the wheel and a point where they are removed. The hub of the star wheel functions as a plenum for low pressure, high flow vacuum, and short openings are provided between the plenum and the pockets. One of the walls of the hub is stationary and, at its periphery, it is positioned closed to but slightly spaced from the rim of the star wheel. A blocking surface is provided within the plenum spaced with a small gap from the inner end of some, but not all, of the short openings, so that vacuum is blocked from some positions of the pockets as they rotate. The apparatus avoids wear and friction, is able to transport irregular shaped articles, and is less costly to manufacture and use.