Integrated Tag Stacking Machine with Suction Feed
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Solution Overview
Problem
Traditional machines for producing stacks of tags are inefficient due to control difficulties, slowness, high operator requirements, low precision, and safety concerns, especially when handling large numbers of tags with variable codes or dimensions.
Innovation Solution
A fully automatic machine that integrates a feed station, individualizing station, advancement station, longitudinal cutting station, transverse cutting station, and stacking station, utilizing controlled belts, rollers, suction units, and optical sensors to precision-cut and stack tags with adjustable dimensions and sequencing based on pre-printed codes, eliminating the need for multiple operators and specialized dies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional separate machines (card cutters, rotary bitted drills, column stackers, punches) are used to produce stacks of tags, then each specific operation can be performed, but control difficulty increases, operating slowness occurs, large number of operators are required, and precision is low
Solution Approach 1:
The patent combines multiple separate machines (card cutter, rotary bitted drill, column stacker, and punch) into a single integrated machine that performs all operations sequentially. This merging eliminates the need for multiple independent machines and operators, reduces control difficulty, and improves overall productivity while maintaining precise control over each operation.
Solution Approach 2:
The integrated machine is designed with universal functionality to perform multiple operations: cutting sheets into strips, drilling holes, stacking columns, and punching tags. This multi-functional design allows a single machine to replace several specialized machines, reducing device complexity and operator requirements while maintaining high productivity.
2Productivity
If card cutter makes cuts on packs consisting of multiple sheets, then processing is faster, but the result accuracy is not particularly accurate
Solution Approach 1:
The machine processes sheets individually rather than in packs, segmenting the processing into single-sheet units. This segmentation allows for precise positioning and cutting of each sheet while maintaining high processing speed through automated sequential operation, thereby achieving both accuracy and productivity.
3Productivity
If column stackers are used during intercalation, then stacking is performed, but constraints are linked to the number of cards to be stacked and their format
Solution Approach 1:
The stacking mechanism is designed to be dynamic and adaptable, allowing adjustment of stacking parameters based on the number and format of tags being processed. The machine can automatically adjust to different tag sizes and quantities, eliminating the rigid constraints of traditional column stackers while maintaining high stacking productivity.
4Manufacturing precision
If punch cutting tools require dies to be purposely created for each specific tag type, then precise tag shaping is achieved, but production cost and complexity increase
Solution Approach 1:
The machine uses a digital copying system where tag designs are stored as programmable patterns. Instead of requiring physical dies for each tag type, the system creates precise cuts by copying digital templates, eliminating the need for expensive custom die creation while maintaining high tagging precision.
5Productivity
If punch cutting tools make cut without separating the cut part, then continuous processing is maintained, but tag separation becomes difficult
Solution Approach 1:
The machine maintains continuous processing by keeping tags connected during cutting and separation operations. Tags remain attached to the sheet throughout the process, and separation is achieved cleanly at the end, ensuring both continuous production flow and easy tag separation without disrupting the processing rhythm.
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 machine achieves high productivity (up to 33,000 tags per hour), precision, and safety with a single operator, allowing for easy variation in tag dimensions and sequencing, reducing production costs and operator stress.
Implementation Method 1
a suction unit for extracting the sheet from the pack
Data Source
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AI summary
A machine (2) for producing stacks (8) of tags (6) starting from at least one sheet (4) on which said tags (6) are printed in ordered manner on one or both its surfaces, comprising in sequence: - a station (10) for feeding at least one sheet (4), - a station (32) for advancing one sheet (4) at a time, - a station (40) for longitudinally cutting said advanced sheet (4) into strips (41), - a station (54) for transversely cutting said strips (41 ) into rows (57) of tags (6) of length (59) corresponding to the length of said tags (6) to be stacked, - a stacking station (60) provided with a stacker (68), into which the tags (6) of each of said rows (57) are discharged one on another, in sequence, to form stacks (8) of tags (6), and - a unit (16) for controlling and coordinating the operations performed in said stations (10, 32, 40, 54, 60), wherein: - said advancement station (32) comprises at least one perforated suction belt (36) for the purpose of stably retaining said sheet (4), - said longitudinal cutting station (40) divides said advanced sheet (4) into strips (41 ) of width (43) corresponding to the width of said tags (6) to be stacked.