Transfer Star Wheel for Empty Containers
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Solution Overview
Problem
Existing transfer star wheel systems for empty containers are complex and expensive to manufacture, install, and maintain, requiring significant machine shutdowns and spare parts storage due to the need for coordinated rotating star wheels and frequent part replacements when container formats change.
Innovation Solution
A transfer star wheel with a rotating structure and stationary structure, equipped with first and second gripping elements, utilizing a vertical movement mechanism and circumferential movement mechanism to rearrange containers from a pitch-separated alignment to a half-pitch-separated alignment, facilitated by suction cups with radially equal suction ports, allowing for easier assembly and maintenance, and adaptable to different container formats without part changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If two rotating star wheels (transfer star wheel and intercalation star wheel) are used to transfer containers from two levels to output conveyor, then container transfer function is achieved, but device complexity and manufacturing cost increase significantly
Solution Approach 1:
The patent merges the functions of two separate rotating star wheels (transfer star wheel and intercalation star wheel) into a single rotating star wheel structure. This single star wheel has gripping elements that can simultaneously handle containers from both upper and lower levels, transferring them to the output conveyor while intercalating them in alternating positions. This consolidation reduces the number of rotating components from two to one, thereby simplifying the device structure and reducing manufacturing complexity while maintaining the container transfer function.
Solution Approach 2:
The single rotating star wheel is designed with multi-functionality to perform both transfer and intercalation operations. It has gripping elements distributed around its periphery that can engage with containers from different levels (upper and lower) and transfer them to alternating positions on the output conveyor. This universal design allows one component to replace multiple specialized components, reducing overall device complexity while achieving the same functional outcome.
2Adaptability or versatility
If two rotating star wheels with coordinated opposite directions are used, then container transfer and intercalation are achieved, but coordination complexity and maintenance difficulty increase
Solution Approach 1:
The patent combines the intercalation function previously performed by a separate intercalation star wheel into the main rotating star wheel. The gripping elements on the single star wheel are arranged to pick up containers from both upper and lower levels and deposit them in alternating positions on the output conveyor, achieving intercalation without requiring a second independently controlled rotating component. This eliminates the need for coordinating opposite rotation directions and different tangential speeds between two star wheels.
Solution Approach 2:
The rotating star wheel is designed with universal gripping elements that can handle both transfer and intercalation operations in a single rotation cycle. The gripping elements are positioned and timed to engage containers from different levels and release them in alternating sequence on the output conveyor, integrating multiple functions into one operational mechanism and eliminating complex coordination requirements.
3Reliability
If fixed gripping elements are used on the rotating star wheel, then container gripping is reliable, but adaptability to different container formats decreases
Solution Approach 1:
The gripping elements on the rotating star wheel are designed to be movable or adjustable rather than fixed. They can dynamically adapt their position and gripping force to accommodate different container formats, sizes, and shapes. This dynamic capability allows the same gripping mechanism to reliably handle various container types by adjusting its configuration, thereby maintaining gripping reliability while achieving format adaptability.
Solution Approach 2:
The gripping elements can change their operational parameters (such as position, orientation, or gripping force) to match different container formats. This parameter adjustability allows the gripping mechanism to maintain reliable contact and control with containers of varying dimensions and characteristics, enabling the system to adapt to different container types without sacrificing gripping reliability.
4Adaptability or versatility
If complex fittings and multiple parts are used for different container formats, then container handling capability is improved, but machine shutdown time and spare parts storage needs increase
Solution Approach 1:
The rotating star wheel is designed with universal gripping elements that can handle multiple container formats without requiring format-specific replacement parts. The same gripping mechanism can be adjusted to accommodate different container sizes and types, eliminating the need for a inventory of spare parts for different formats and reducing machine shutdown time for part replacements.
Solution Approach 2:
The dynamic and adjustable nature of the gripping elements allows them to adapt to different container formats through parameter changes rather than physical part replacements. This eliminates the need for complex fittings and multiple specialized parts, thereby reducing maintenance downtime and spare parts storage requirements while maintaining the ability to handle various container types.
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 manufacturing, installation, and maintenance of the transfer star wheel, reduces machine shutdown times, and minimizes spare parts storage needs by using a single rotating structure to perform vertical and circumferential movements, ensuring efficient container transfer without format-specific part replacements.
Implementation Method 1
The first and second gripping elements are respectively made up of suction cups
Data Source
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AI summary
The invention relates to a transfer star wheel comprises a vertical-axis rotational structure (26) and a stationary structure (27), a vertical movement mechanism for moving first gripping elements along first guiding elements from an upper level at an inlet site (28) to a lower level at an outlet site (29) and again to the upper level at the inlet site in the course of each turn, and a circumferential movement mechanism for moving second gripping elements along second guiding elements from a position corresponding to a pitch (P) at the inlet site to a position moved half a pitch (P/2) at the outlet site and again to the circumferential position corresponding to the pitch (P) at the inlet site in the course of each turn of the rotational structure (26).