Tray Sealing Machine Gripper Timing Optimization
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Solution Overview
Problem
The operation of shell sealing machines is inefficient due to limitations in cycle time caused by the gripper's interference between the sealing tool base and top, leading to high accelerations that can result in product protrusion or instability, especially with sensitive contents.
Innovation Solution
The method involves the simultaneous upward movement of the support plate and sealing tool base during the closing of the sealing tool chamber, allowing for faster and more controlled movements without abrupt accelerations, and the downward extension of the support plate during opening, enabling earlier gripper engagement and reduced cycle times.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the gripper waits for the lower sealing tool to stop before engaging the packaging tray, then the tray can be securely grasped, but the cycle time increases and productivity decreases
Solution Approach 1:
The gripper moves into the sealing tool chamber in advance and positions itself to grasp the packaging tray while the lower sealing tool is still moving downward, rather than waiting for the tool to come to a complete stop. This preliminary positioning allows the gripper to engage the tray during the motion phase, reducing idle time and accelerating the overall cycle without compromising engagement reliability
2Productivity
If the lower sealing tool moves upward at high speed to reduce cycle time, then productivity improves, but high accelerations cause product protrusion or instability
Solution Approach 1:
The system employs dynamically adjustable acceleration and deceleration phases for the lower sealing tool movement. By optimizing the motion profile to use higher accelerations only when necessary and reducing acceleration during product-sensitive phases, the system achieves faster overall cycle times while maintaining product stability. The gripper's early engagement also allows for more flexible dynamic control of the sealing tool movement
3Reliability
If the gripper remains stationary inside the sealing tool chamber during the sealing process, then the sealing operation can be completed, but the cycle time increases by 150-200 ms
Solution Approach 1:
The gripper begins moving the sealed packaging tray outward from the sealing tool chamber while the sealing operation is still in progress, rather than remaining stationary and waiting for sealing to complete. This overlapping of operations—where the gripper's tray extraction movement occurs concurrently with the sealing process—eliminates idle time and reduces the total cycle time by 150-200 ms while ensuring the sealing operation completes successfully
Data Source
Figure 1
Figure 2A~2D
AI summary
Method for operating a tray sealing machine (1) comprising: gripping a packaging tray (11) by means of a gripper (9), placing the packaging tray (11) on a backing plate (15) in the area of an interior (8) of an open sealing tool chamber (7), which comprises a sealing tool upper part (5) and a sealing tool lower part (3), sealing the packaging tray (11), gripping the packaging tray (11) and placing it away from the backing plate (15), wherein A) after placing the packaging tray (11) on the backing plate (15) the backing plate (15) is lifted and at least in phases the gripper (9) is simultaneously extended out of the area of the interior (8), and the sealing tool lower part (3) is lifted until it contacts the sealing tool upper part (5), wherein at least in phases the backing plate (15) simultaneously performs a relatively slower upward movement than the sealing tool lower part (3) and thus in the lower part of the sealing tool (3) retractsfollows, and/or B) after the packaging tray (11) is sealed, the lower part of the sealing tool (3) is lowered, whereby at least in phases the support plate (15) simultaneously performs a relatively slower downward movement than the lower part of the sealing tool (3) and is thus extended from the lower part of the sealing tool (3).