Suction Cup Separator for Nested Plastic Trays
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for separating stacked products, such as nested plastic trays, are complex, time-consuming, and operator-dependent, especially in high-pressure environments like meat processing, where products often stick together due to varying dimensions and rigidity, making mechanical separation difficult.
Innovation Solution
A device with product stops that are adjustable and inclined to allow gravity-induced sliding, combined with a suction cup for gentle gripping and pulling, allows for easy conversion to new products without extensive parameter adjustments, using a format plate with guide pins for precise positioning and a pneumatic cylinder for controlled extraction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If lifting wedges or spirals are used to separate nested shells, then separation can be achieved, but the device becomes complex and requires time-consuming manual adjustment for each shell type
Solution Approach 1:
The patent replaces complex mechanical lifting wedges or spirals with a simple suction cup system that uses vacuum pressure to grip and separate shells. This substitution eliminates the need for complex adjustable mechanical components while maintaining reliable separation across different shell types.
Solution Approach 2:
The invention changes the separation mechanism from mechanical lifting to pneumatic suction, altering the fundamental parameter from mechanical force to vacuum pressure. This allows the same basic mechanism to handle various shell types without manual adjustment, as the suction force can be uniformly applied regardless of shell dimensions.
2Manufacturing precision
If multiple parameters are adjusted for each new shell type, then separation quality improves, but operator time and experience requirements increase
Solution Approach 1:
The patent segments the separation function into a self-contained suction cup module that operates independently of shell-specific parameters. This modular approach allows the same component to handle different shell types without requiring parameter adjustments, eliminating the need for operator expertise in optimizing multiple settings.
Solution Approach 2:
The suction cup system performs separation automatically based on vacuum pressure application, without requiring operator intervention for parameter adjustment. The system serves itself by adapting to different shell types through the universal application of suction force, eliminating dependency on operator time and experience.
3Reliability
If mechanical force is applied to separate rigid shells, then separation can be achieved, but product damage risk increases
Solution Approach 1:
The patent replaces direct mechanical contact and force application with a pneumatic suction system. The suction cup grips the shell edge and pulls it away from nested shells using vacuum pressure, eliminating the need for mechanical wedges or levers that could damage rigid or thin-walled products.
Solution Approach 2:
The suction cup acts as an intermediary between the separation mechanism and the shell, providing a gentle yet effective gripping interface. This intermediary component transfers vacuum pressure to the shell edge without requiring direct mechanical contact that could cause damage to fragile or thin-walled products.
4Loss of substance
If plastic trays are made thinner to save costs, then material cost decreases, but dimensional stability and separation difficulty worsen
Solution Approach 1:
The patent replaces mechanical separation methods that struggle with thin, flexible trays with a suction-based system. The vacuum pressure applied by the suction cup effectively grips the edge of thin plastic trays without requiring the dimensional stability needed for mechanical wedge or spiral separators to function properly.
Solution Approach 2:
The invention changes the separation approach from mechanical force application to pneumatic suction, which is particularly effective for thin-walled plastic trays. The vacuum pressure adapts to the flexibility of thin materials, providing reliable separation without requiring the trays to maintain rigid dimensional stability.
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 solution simplifies the separation process, reduces operator error, and allows for efficient handling of products of different sizes and rigidity, ensuring reliable separation with minimal damage and quick adaptation to new products, enhancing throughput and reducing operational complexity.
Implementation Method 1
The bottom, first product, which rests directly on the stops, is then gripped from the removal side opposite the supply side and pulled through the stops and deposited individually... The gripping and pulling through is preferably done by means of a suction cup
Implementation Method 2
the stack of products is not perpendicular to the product stops, but inclined at an angle that is just sufficient to allow the stack to slide down to the stops due to the force of gravity
Data Source
Figure 1a
Figure 1b
Figure 1c
AI summary
The device has a feed device (4) which feeds the stacked products (50) along a path of travel. A product stop protrudes into the movement path of the stack products, when the plane of the abutment holder (2) is offset in the direction of the feed side portion. The stack product on the consumption side is taken away, to draw a removal device on the supply side opposite to the consumption side. The product stop is adjusted between the retaining position and the release position, when the outer edge portion of the stack products is elastic. An independent claim is included for method for separating stacked product.