Tray Sealer Gripper Carriage Control for Faster Changeover
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Solution Overview
Problem
Existing tray sealing machines have inefficiencies in the removal of sealed trays from the sealing station and transport of unsealed trays into the sealing station, leading to suboptimal cycle rates and product quality.
Innovation Solution
A tray sealing machine with coordinated control of gripper units to maintain a predetermined minimum distance between carriages during the closing and adjustment movements, ensuring efficient tray changeover by optimizing the timing and coordination of gripper movements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the sealing station is kept open for tray removal and insertion, then tray changeover can be performed, but the cycle time increases and productivity decreases
Solution Approach 1:
The first carriage is advanced in the production direction before the sealing station is fully opened, so that when the second gripper closes to pick up trays, the first carriage is already positioned close to the sealing station. This preliminary positioning reduces the time the sealing station remains open and enables faster tray changeover.
Solution Approach 2:
The control device coordinates the movements continuously so that while the second gripper is closing to pick up sealed trays, the first carriage is simultaneously advancing to position unsealed trays. This continuous coordinated action eliminates idle time and maintains productive operation throughout the tray changeover process.
2Productivity
If the first and second carriages are positioned close together for fast tray changeover, then productivity increases, but the risk of collision increases
Solution Approach 1:
The control device monitors the positions of both carriages and the state of the lifting mechanism in real-time, dynamically adjusting the movements to maintain the predetermined minimum distance. This feedback control ensures that the carriages approach each other as closely as possible without risking collision.
Solution Approach 2:
The control device establishes a predetermined minimum distance between the first and second carriages before they approach each other during tray changeover. This preventive measure ensures that even if movements are accelerated for productivity, the safety buffer prevents collision.
3Adaptability or versatility
If independent control of first and second grippers is used, then operational flexibility is improved, but coordination efficiency for tray changeover decreases
Solution Approach 1:
The control device merges the independent control functions of the first and second grippers into a coordinated system. While maintaining the ability to control each gripper independently, the control device synchronizes their movements so that the first carriage advancement and second gripper closing occur in optimal sequence, improving tray changeover efficiency without sacrificing operational flexibility.
Data Source
Figure 1
Figure 2A~2B
Figure 3A~3D
AI summary
Tray sealing machine (1) comprising a sealing station (2) for sealing trays (3), a feed conveyor (4) for providing trays (3), a discharge conveyor (5) for transporting sealed trays (3), a gripper device (6) comprising a first gripper unit (7) configured to pick up trays (3) from the feed conveyor (4) and position them within the sealing station (2) for a sealing operation, and a second gripper unit (8) configured to pick up the trays (3) sealed by the sealing station (2) and position them on the discharge conveyor (5) for transport, wherein the first gripper unit (7) comprises a first carriage (9) and a first gripper (10) mounted thereon, and the second gripper unit (8) comprises a second carriage (11) and a second gripper (12) mounted thereon, and a lifting mechanism (13) for opening and closing the sealing station (2).and a control device (14) for controlling a movement of the first carriage (9) and the first gripper (10) and for controlling a movement of the second carriage (11) and the second gripper (12), wherein the control device (14) is configured to control, during the opening of the lifting mechanism (13), both a closing movement (S) of the second gripper (12) carried out transversely to the production direction (R) for picking up sealed trays (3) from the sealing station (2) and an adjustment movement (V) of the first carriage (9) carried out in the production direction (R) for feeding unsealed trays (3) into the sealing station (2) such that there is essentially a predetermined minimum distance (x) between the first and the second carriage (9, 11),when the closing movement (S) of the second gripper (12) is at least substantially completed. Furthermore, the invention relates to a method for controlling a gripper device (6) of a tray closing machine (1).