Suspended Card Stacking via Suction Conveyor and Air Detachment
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Solution Overview
Problem
Existing devices for stacking card-shaped data carriers, such as chip cards, require manual handling and processing, leading to inefficiencies and low throughput rates, as they need to be transported, counted, and manually stacked in card magazines for packaging and further processing.
Innovation Solution
A device with a conveyor system that suspends and transports card-shaped data carriers, allowing for selective transfer and stacking directly into card magazines without intermediate processing, using suction and air flow for detachment and alignment, and incorporating features like antistatic brushes and centering devices to enhance efficiency and accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual handling and processing is used for transporting and stacking card-shaped data carriers, then operational flexibility is maintained, but process speed and productivity are reduced
Solution Approach 1:
The patent replaces manual mechanical handling with an automated conveyor system that uses suction forces to transport and position card-shaped data carriers. The conveyor belt with suction openings automatically moves cards through the stacking process, eliminating the need for manual picking and placement operations.
Solution Approach 2:
The system enables self-service automation where the conveyor belt automatically transports cards, the stacking unit automatically detects and positions cards in card magazines, and the entire process operates without continuous manual intervention. The suction mechanism automatically holds and releases cards at designated positions.
2Productivity
If manual counting and packaging is performed, then accuracy can be verified, but time consumption increases
Solution Approach 1:
The patent implements continuous automated operation where cards are constantly being transported on the conveyor belt, stacked in card magazines, and packaged without interruption. The system operates continuously from feed to output, eliminating the stop-start nature of manual counting and packaging operations.
Solution Approach 2:
Cards are automatically counted and positioned in card magazines during the transport process itself, rather than requiring separate post-transport counting operations. The stacking unit pre-arranges cards in the correct quantities and positions within magazines while they are being conveyed, eliminating subsequent manual sorting.
3Productivity
If cards are transported individually through the device, then processing precision is maintained, but handling complexity increases
Solution Approach 1:
The conveyor belt serves multiple functions simultaneously: it transports cards, holds cards via suction, positions cards for stacking, and guides cards through the entire processing path. The stacking unit also performs multiple functions including detecting card positions, counting cards, and coordinating with card magazines. This multi-functionality reduces the need for separate dedicated components.
Solution Approach 2:
The patent merges the transportation and stacking functions into an integrated system where the conveyor belt and stacking unit operate as a coordinated unit. The suction mechanism combines holding and releasing functions, and the control system coordinates all operations as a unified process rather than separate discrete operations.
4Reliability
If cards are held on the conveyor belt, then transport stability is improved, but detachment precision for stacking must be maintained
Solution Approach 1:
The suction force on the conveyor belt is applied periodically - strong suction to firmly hold cards during transport, then reduced or interrupted suction at designated detachment points to allow precise release. This periodic variation in suction strength enables both stable transport and precise detachment when needed for stacking.
Solution Approach 2:
The patent uses the suction force as an intermediary mechanism that can be precisely controlled to both secure cards during transport and release them at specific moments. The suction openings in the conveyor belt act as intermediaries that mediate between the card and the conveyor surface, allowing controlled adhesion and detachment without mechanical gripping.
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
This solution significantly increases the process speed and productivity, enabling high-throughput stacking of card-shaped data carriers, potentially up to 36,000 disks per hour, by eliminating manual handling and ensuring precise alignment and electrical discharge, thus improving the overall efficiency and reliability of the stacking process.
Implementation Method 1
The conveyor device (4) is set up to convey the card-shaped data carriers (5) in such a way that they are fixed to it in a suspended transport manner
Implementation Method 2
for selectively releasing a specific data carrier conveyed along the conveyor device, to which a mechanical impulse is transmitted by blowing off the data carrier from the conveyor device
Implementation Method 3
The device (1) furthermore has at least one discharge element (7), in particular one or more antistatic brushes, which are configured to at least partially electrically discharge the data carriers (5) before or immediately after they are released from the conveyor device (4)
Data Source
Figure 1
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Figure 3
AI summary
The invention relates to a device (1) and to a method for stacking card-shaped data carriers (5). The device has (i) a conveying apparatus (4) for transporting isolated card-shaped data carriers downstream along a conveying path and (ii) a stacking unit (2) for selectively transferring and stacking card-shaped data carriers conveyed along the conveying path. The conveying apparatus is designed to convey the card-shaped data carriers in such a way that the card-shaped data carriers are fastened to the conveying apparatus for suspended transport. The stacking unit is designed to detach selectively determined card-shaped data carriers of the card-shaped data carriers conveyed along the conveying apparatus from the conveying apparatus in order to transfer said card-shaped data carriers directly into a card magazine (8; 8a, 8b), i.e. in particular without intermediate processing, intermediate transport or intermediate storage, and to stack said card-shaped data carriers therein when said card magazine is arranged in a stacking position (24) in a stacking region (C), said stacking position being located below the conveying path with respect to the direction of gravity.