Automatic Tray Feeder Vacuum Suction Mechanism
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Solution Overview
Problem
Existing machines for feeding and dosing small trays or boxes to bakery product wrapping machines often damage the trays due to compression, affecting the quality of the wrapped products and are not suitable for stacked, uncompressed trays.
Innovation Solution
An automatic feeder system using a piston-activated suction cup with a vacuum mechanism that extracts and releases small trays individually, preventing damage by using a support structure with a compartment and backstops to maintain tray alignment, and a vacuum breaking mechanism to allow gravity-assisted tray release onto a conveyor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If mechanical pressure is applied to compact and stack boxes using plier elements, then the boxes can be fed continuously to the conveyor, but the small boxes and trays are damaged affecting the final quality
Solution Approach 1:
The patent replaces the mechanical plier-based compression system with a vacuum suction system. The piston with suction cup uses vacuum pressure to extract and transfer trays individually without mechanical contact, eliminating the damage caused by plier elements while maintaining continuous feeding capability
Solution Approach 2:
The invention uses pneumatic principles through the vacuum suction cup activated by a piston. The vacuum pressure field enables tray extraction and transfer without mechanical compression, resolving the contradiction between continuous feeding and tray integrity by using fluid pressure instead of mechanical force
2Ease of operation
If transverse arms with rubber insertions are used to dose boxes mechanically, then the boxes can be separated and fed to the wrapping feeder, but the small trays are damaged during the dosing process
Solution Approach 1:
The patent replaces the mechanical arm-based dosing system with a vacuum suction-based extraction system. The suction cup attached to a piston retrieves trays individually through vacuum adhesion, eliminating mechanical contact that causes damage while achieving the same individual separation and dosing function
3Manufacturing precision
If a vacuum suction cup is used to extract trays individually, then the trays can be fed precisely and continuously without damage, but the device complexity increases due to the piston and vacuum mechanism
Solution Approach 1:
The piston mechanism serves multiple functions: it generates vacuum pressure for tray extraction, controls the timing of tray release through its reciprocating motion, and positions the suction cup accurately. This multi-functionality reduces the need for separate components, thereby limiting the increase in device complexity despite the advanced dosing precision achieved
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
Enables precise, continuous, and damage-free dosing of small trays to bakery product wrapping machines, ensuring the quality of the wrapped products and improving operational efficiency.
Implementation Method 1
A vacuum may be generated in the suction cup to extract small trays on an individual basis
Implementation Method 2
When the piston is extended, a vacuum is generated in the suction cup sufficient to hold the tray
Implementation Method 3
Breaking the vacuum in the suction cup releases the tray so that the tray falls by gravity onto a ramp
Data Source
AI summary
An automated feeder may allow continuous and synchronized feeding of small trays to equipment for subsequent processing. Automated feeder includes a piston with a suction cup on a distal end. The suction cup may contact and extract via a vacuum trays disposed in a compartment disposed in front of the piston. The compartment may include a frame with rods projecting perpendicularly and at least one backstop to inhibit movement of the trays. A vacuum breaking means may be disposed between the piston and the frame, such that during extension of the piston a vacuum is generated to hold a tray. When the piston is retracted, the tray is pulled from the compartment, partially deforming corners of the tray which releases the tray from backstop(s) of the frame. The small tray falls down by gravity and is taken by a ramp to a conveyor to equipment for subsequent processing.