Vacuum Head Segmentation for Uniform Palletizing
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Solution Overview
Problem
Conventional vacuum head systems for palletizing loose-piece articles are unreliable, require large and expensive motors, and can damage thin-walled containers due to uneven vacuum distribution and high airflow, leading to inefficiencies and increased costs.
Innovation Solution
A movable vacuum head with a frame, blower, and manifold that uses a slipsheet to distribute vacuum uniformly across its surface, allowing for efficient pickup and transport of loose-piece articles without damaging them, utilizing a smaller motor and reducing operational costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single opening vacuum head is used to create vacuum from the center, then the vacuum can be applied to containers, but the large air flow draws containers toward the vacuum head causing unreliability and requiring large expensive motors
Solution Approach 1:
The vacuum head is segmented into multiple openings distributed across its surface instead of a single center opening. This segmentation distributes the air flow and vacuum force across multiple points, preventing containers from being drawn toward a single center point and eliminating the need for large powerful motors.
Solution Approach 2:
Different regions of the vacuum head surface are equipped with openings to provide locally distributed vacuum application. This local quality approach ensures uniform vacuum distribution across the container surface, improving reliability while reducing the power required compared to a single high-flow center opening.
2Reliability
If vacuum is applied directly to containers using a single opening, then containers can be picked up, but thin-walled containers can collapse due to high air flow
Solution Approach 1:
The vacuum force is segmented into multiple smaller openings rather than one large opening. This distributes the suction force across the container surface, preventing localized high stress that would cause thin-walled containers to collapse while maintaining reliable pickup.
Solution Approach 2:
The vacuum head provides uniform local vacuum quality across multiple contact points with the container. This distributed local quality approach prevents concentrated force that damages thin-walled containers while ensuring reliable handling of all container types.
3Adaptability or versatility
If conventional vacuum heads are used, then containers can be picked up, but the system is unreliable and can only be used with containers having sufficient surface area exposed to the vacuum
Solution Approach 1:
Multiple openings are segmented across the vacuum head surface, allowing the system to adapt to various container shapes and surface areas. This segmentation ensures that sufficient vacuum contact is achieved regardless of container geometry, improving both adaptability and reliability.
Solution Approach 2:
The multi-opening vacuum head design provides universal applicability across different container types and sizes. The distributed openings ensure reliable vacuum pickup for containers with varying surface areas and geometries, making the system versatile and reliable.
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
The solution provides a reliable, cost-effective, and efficient method for palletizing loose-piece articles by ensuring uniform vacuum distribution, reducing the risk of container damage, and maintaining control during transportation, while requiring less power and being quieter in operation.
Implementation Method 1
the blower is activated, a vacuum is created which causes the slipsheet, and the loose-piece articles positioned thereon, to be drawn toward the bottom surface of the manifold
Implementation Method 2
The bottom surface has a plurality of openings which extend through the bottom surface and which are spaced periodically over the entire surface area of the bottom surface
Data Source
AI summary
A method and apparatus for moving loose-piece articles positioned on a slipsheet. A vacuum head is moved into proximity with the loose-piece articles positioned on a slipsheet. A vacuum is created which causes the slipsheet, and the loose-piece articles positioned thereon, to be drawn toward a surface of the vacuum head and maintained in such position as the vacuum head transports the slipsheet and the loose-piece articles positioned thereon.