Tray Loading Station Gripper Pusher Mechanism
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Solution Overview
Problem
Conventional tray sealer loading stations experience reduced throughput due to fully loaded trays occupying space on the tray conveyor for extended periods, adhering to a 'first in-first out' logic that delays the loading process.
Innovation Solution
A method and loading station design where a gripper unit loads trays to a target value and then pushes them directly onto a discharge belt, regardless of their position, implementing a 'first full-first out' logic to free space for other trays and enhance throughput.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If trays are loaded sequentially on a tray conveyor using conventional weight-based loading logic, then the loading process is simple and controlled, but fully loaded trays occupy space on the conveyor for extended periods, reducing throughput rate
Solution Approach 1:
The system determines when a tray is fully loaded based on target weight or product count before the tray reaches the discharge position. This preliminary determination allows the system to prepare for immediate discharge without waiting for the tray to naturally move to the discharge position, thereby reducing the time fully loaded trays occupy conveyor space.
Solution Approach 2:
The loading station continuously monitors the loading status of trays and uses this feedback to control the discharge timing. When a tray reaches the target weight or product count, the system immediately triggers discharge preparation, creating a closed-loop control that optimizes conveyor utilization and increases throughput rate.
2Productivity
If a mechanical pusher is used to discharge trays at the discharge position, then the discharge process is simple, but only the foremost tray can be discharged at a time, causing delays when multiple trays are fully loaded
Solution Approach 1:
The discharge function is segmented and distributed across multiple gripper units positioned at different locations on the conveyor. Each gripper unit can independently discharge trays that are fully loaded at its position, eliminating the bottleneck of a single mechanical pusher and allowing parallel discharge operations to increase throughput rate.
Solution Approach 2:
The gripper units serve multiple functions: they load products onto trays, monitor loading status, and discharge fully loaded trays. This multi-functionality eliminates the need for separate dedicated discharge mechanisms, maintaining operational simplicity while enabling higher throughput through parallel processing capabilities.
3Productivity
If the loading station waits for trays to reach the discharge position naturally, then the conveyor operation is simple, but the loading process is delayed and throughput is reduced
Solution Approach 1:
The system performs preliminary discharge preparation when trays are detected to be fully loaded at intermediate positions on the conveyor, rather than waiting for trays to reach the discharge position naturally. This preliminary action reduces the time trays spend on the conveyor and increases throughput while maintaining relatively simple operational control through automated detection and triggering.
Data Source
AI summary
The disclosure relates to a method for inserting products into trays at a loading station for a tray sealer, where a tray of several trays loaded with product by way of a gripper unit to a target value at the loading station and provided therein on a tray conveyor is pushed directly onto a discharge belt of the loading station by way of a tray pusher formed on the gripper unit. The disclosure furthermore relates to a loading station for a tray sealer.