Tray Feeder with Independent Chains for Continuous Sealing
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Solution Overview
Problem
Existing tray sealers with intermittently operating chain feeders are not ergonomic for staff and result in downtime due to errors from missing or incorrectly inserted trays, leading to productivity issues.
Innovation Solution
A tray feeder system with at least two independently driven train chains, each equipped with pusher elements, allows for continuous operation without gaps between tray groups, ensuring complete trains are collected and transported to the sealing station without halting the chain feeder.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a continuously moving chain feeder is used to improve ergonomics and manual loading efficiency, then ease of operation is improved, but downtime increases due to halts caused by missing or incorrectly inserted trays
Solution Approach 1:
The system divides the continuous chain feeder operation into discrete tray groups (trains) that are independently handled. Each group is collected, verified for completeness, and processed separately by the gripper system, allowing continuous operation without halts for individual tray errors.
Solution Approach 2:
The patent introduces an intermediary verification mechanism between the chain feeder and the gripper system. Sensors detect the presence and correct insertion of trays, and the control system mediates the flow by allowing complete groups to pass while blocking or alerting on incomplete groups, preventing downtime.
2Adaptability or versatility
If gaps are provided between groups of trays on the chain feeder to enable grouping, then tray grouping capability is improved, but productivity decreases due to unnecessary halts and reduced continuous operation
Solution Approach 1:
The system dynamically adjusts the grouping process by using sensors to detect tray presence and control signals to regulate the flow from the continuous chain feeder. Groups are formed on-demand without fixed gaps, allowing the system to maintain continuous operation while adapting group formation to actual tray availability.
Solution Approach 2:
The patent implements a feedback control system where sensors continuously monitor tray presence and insertion correctness. This feedback is processed by the control system, which adjusts the grouping process in real-time, allowing complete groups to be identified and transferred without halting the chain feeder, thus maintaining productivity.
3Manufacturing precision
If sensors are used to detect tray presence and ensure correct grouping, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The control system performs multiple functions: it receives signals from sensors, verifies tray presence and correct insertion, determines group completeness, controls the timing of gripper operations, and manages the continuous flow from the chain feeder. This multi-functionality reduces the need for separate complex subsystems while maintaining high precision.
Data Source
AI summary
A tray sealer that may be incorporated into a packaging facility, the tray sealer may include a tray feeder for collecting a plurality of trays that are conveyed on a continuously moving chain feeder. An embodiment of the tray feeder may comprise at least two train chains. Each train chain may be independently moveable and each train chain may be operable grouping the plurality of the trays into groups and transferring the groups to a sealing station. The group of trays may have number of trays that corresponds to the operation of the sealing station. The tray sealer may include the transfer of a group of trays by a gripper system to a sealing station of the tray sealer.