Tray Transfer Layout for Compact High-Speed Cartridge Assembly
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing manufacturing machines for disposable electronic cigarette cartridges face challenges in achieving high productivity while maintaining a compact transverse bulk, as wide linear electric motors complicate precise slide control and the use of multiple conveyors either slows down production or increases machine width, making operator access difficult.
Innovation Solution
A manufacturing machine design featuring a series of processing conveyors with a single transfer unit that uses a moving system with trays and transfer devices to efficiently move cartridges between conveyors, allowing for high-speed operation and compact dimensions by optimizing the layout and orientation of cartridges during transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single wide assembly conveyor with linear electric motor is used, then the machine width increases, but precise control of slides at high productivity becomes difficult
Solution Approach 1:
The patent divides the manufacturing system into multiple assembly conveyors (first assembly conveyor and second assembly conveyor) arranged in series, each with limited extension. This segmentation allows each conveyor to maintain precise control of slides while operating at high productivity, avoiding the control difficulties of a single wide conveyor.
Solution Approach 2:
The patent introduces a transfer unit as an intermediary between the first and second assembly conveyors. This transfer unit cyclically transfers disposable cartridges between the two conveyors, enabling the system to achieve high productivity through coordinated operation of multiple conveyors while maintaining precise control on each individual conveyor.
2Ease of operation
If two assembly conveyors are arranged coplanar with robotic arm transfer, then transfer capability is achieved, but productivity decreases due to long transfer path
Solution Approach 1:
The patent transitions from coplanar arrangement to a three-dimensional staggered arrangement of the two assembly conveyors. By positioning the conveyors at different heights (one above the other) with an overlapping area, the transfer unit can execute very short straight strokes perpendicular to the conveyors, dramatically reducing transfer time and maintaining high productivity.
3Productivity
If two assembly conveyors are arranged parallel and staggered for short transfer stroke, then transfer speed increases, but machine width and overall dimensions increase significantly
Solution Approach 1:
The patent utilizes the vertical dimension by arranging the two assembly conveyors at different heights in a staggered configuration. This three-dimensional arrangement allows the transfer unit to move cartridges between conveyors through short perpendicular strokes, achieving high transfer speed without increasing the horizontal footprint or overall machine width.
4Adaptability or versatility
If linear electric motor is made very wide for necessary space, then assembly operations can be performed, but control of multiple slides becomes very difficult
Solution Approach 1:
The patent segments the assembly system into multiple separate conveyors, each with a limited number of slides. This segmentation reduces the control complexity for each individual conveyor while maintaining the capability to perform multiple assembly operations across the distributed system through coordinated operation and the transfer unit.
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
This design enables high hourly production rates with improved precision and accessibility, ensuring efficient assembly, maintenance, and cleaning operations while maintaining a modest transverse bulk.
Implementation Method 1
the assembly conveyor must be particularly wide in order to have the necessary space. However, when the linear electric motor is very wide it necessarily comprises a large number of slides
Data Source
Figure 1~2
Figure 3
Figure 4
AI summary
A manufacturing machine (5) to manufacture a product (1) and provided with a feeding system (7) to feed the products (1) along a horizontal, straight processing path (P1). The feeding system (7) has: a first processing conveyor (9), a second processing conveyor (10), which is arranged in series with the first processing conveyor (9) along the processing path (P1), and a transfer unit (11) which is interposed between the two processing conveyors (9, 10) and cyclically transfers the products (1) from the first processing conveyor (9) to the second processing conveyor (10), picking up the products (1) in a pick-up station (S4) arranged in the area of the first processing conveyor (9) and releasing the products (1) in a release station (S5) arranged in the area of the second processing conveyor (10). The transfer unit (11) has: a plurality of trays (19), each having a series of seats (20), each designed to house a product (1), a moving system (21), which cyclically moves the trays (19) between the pick-up station (S4) and the release station (S5), a first transferring device (22), which is arranged in the pick-up station (S4) so as to transfer the products (1) from the first processing conveyor (9) to a tray (19), and a second transferring device (23), which is arranged in the release station (S5) so as to transfer the products (1) from a tray (19) to the second processing conveyor (10).