Thermoforming Holding Element Sensor Integration
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Solution Overview
Problem
In thermoforming machines, it is difficult to detect the absence of products from multiple holding members, especially when there are many, leading to inefficiencies in product transfer and potential damage due to incomplete transfer processes.
Innovation Solution
The implementation of sensor elements, such as optical, inductive, or capacitive sensors, on each holding member to monitor product presence and absence, allowing for reliable detection and control of the transfer process, with the option of connecting them in series or parallel to minimize cabling and enhance reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sensor elements are arranged on each holding member to monitor product presence, then detection reliability is improved, but device complexity increases
Solution Approach 1:
The monitoring system is segmented by placing individual sensor elements on each holding member, enabling independent detection of product presence at each location. This segmentation allows the system to identify exactly which holding member is empty, improving detection reliability while maintaining manageable complexity through modular sensor placement.
Solution Approach 2:
Optical sensors serve as intermediary elements that detect product presence without direct mechanical contact. The sensors use optical fields as intermediaries to sense whether a product is on the holding member, converting physical presence into detectable optical signals that can be processed by the control system.
2Duration of action of stationary object
If optical sensors are used for non-contact product detection, then service life is improved, but manufacturing complexity increases
Solution Approach 1:
Mechanical contact-based detection systems are replaced with optical sensors that detect product presence through non-contact optical fields. This substitution eliminates mechanical wear on sensors, significantly extending service life, while the sensors can be integrated into existing holding member structures with minimal additional manufacturing steps.
3Reliability
If all holding members are equipped with sensor elements for complete monitoring, then transfer completeness is improved, but cabling complexity increases
Solution Approach 1:
Multiple sensor elements are electrically connected in parallel configuration, merging their signals into a unified monitoring system. This parallel connection allows all holding members to be monitored simultaneously while minimizing cabling complexity, as sensors can share common electrical connections and signal processing pathways rather than requiring independent wiring for each sensor.
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
Ensures complete and reliable transfer of products from the multiple tool to the collection station, preventing subsequent errors and damage by immediately detecting and addressing any incomplete transfers, thereby enhancing process reliability and reducing mechanical stress on products.
Implementation Method 1
The sensor elements are preferably in the form of optical sensors, with the product being detected without contact.
Implementation Method 2
a plate-shaped base body (3), which can be pivoted about a pivot axis (4) and which is fitted on one side with a multiplicity of rigid suction lines (5), on each of which a conically shaped holding member (6) is arranged
Data Source
Figure 1~2
Figure 3~4
AI summary
The invention relates to a device for stacking products made of thermoplastic material dispensed from a multi-tool (1) of a thermoforming machine, comprising at least one, in particular plate-shaped, base body (3), and a plurality of, in particular conically shaped, holding elements (6), wherein each of the holding elements (6) is arranged on the base body (3) by means of a suction line (5), wherein a product can be detachably picked up at each of the holding elements (6) by means of a negative pressure applied to the suction line (5), and wherein the base body (3) with the holding elements (6) and the picked-up products is movable between the multi-tool (1) of the thermoforming machine and a, in particular, stacking collection station (2), wherein a sensor element (10) is arranged on each of the holding elements (6), by means of which the presence and/or absence of a product on the holding element (6) can be detected.