High Speed Telescopic Tray and Hood Fitting via Dynamic Motion
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Solution Overview
Problem
Current indexed processes for telescopically fitting paperboard or corrugate trays and hoods are slow due to start and stop movements, which limit productivity, and residual stresses from folding can cause warping, making consistent fitting challenging.
Innovation Solution
A high-speed process involving a tray carriage system and a hood engagement system where the hood is moved at a higher velocity relative to the tray, with the hood approaching at an angle to facilitate smooth engagement while both are in motion, allowing for precise control of velocities and positioning to overcome the limitations of traditional indexed processes and stress-induced warping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If indexed processes are used with start and stop movements, then control and positioning are simplified, but productivity is reduced due to slow cycle times
Solution Approach 1:
The patent applies dynamics by enabling continuous motion of both the tray and hood through the engagement station rather than using traditional indexed stop-and-start movements. The tray carriage system moves the tray at velocity V1 while the hood is fed at velocity V2, allowing the fitting process to occur during motion. This dynamic approach eliminates the time losses associated with acceleration and deceleration cycles while maintaining precise positioning control through synchronized velocity management.
2Productivity
If greater accelerations and decelerations are used to shorten cycle time, then productivity improves, but forces generated by momentum changes increase
Solution Approach 1:
The system maintains continuous motion at controlled velocities V1 and V2 throughout the engagement process, eliminating the need for high accelerations and decelerations. By keeping the tray and hood in constant motion through the fitting station, the patent avoids generating large momentum forces that would result from rapid speed changes, while still achieving high productivity through optimized velocity parameters and continuous operation.
3Manufacturing precision
If traditional indexed processes are used, then positioning control is easier, but warping from residual stresses causes inconsistent fitting
Solution Approach 1:
The patent applies preliminary action by pre-cooling the tray and hood in cooled chambers before they enter the engagement station. This pre-cooling process allows residual stresses to stabilize and warping to minimize before the fitting operation occurs. By preparing the components in advance under controlled temperature conditions, the system achieves consistent fitting results despite the continuous motion process, as the trays and hoods are dimensionally stable when they engage.
Data Source
AI summary
A process for packaging a product in which a hood is fitted to a tray. The hood top is oriented at an angle relative to the machine direction in which the tray is being conveyed. The hood is engaged with the tray by initiating contact between a leading panel of the hood with the tray while the leading panel is moving before engaging the trailing panel with the tray. As the tray is conveyed in the machine direction, the tray captures a hood by the leading panel of the hood and the remainder of the hood is subsequently fitted to the tray.