Automated Insert Feeding System with Vacuum Picking Mechanism

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Solution Overview

Problem

Conventional insert feeding systems for pharmaceutical containers require constant operator intervention, struggle with high-speed operation, and often lose containment of inserts during the packaging process, especially when transitioning between vertical and horizontal orientations.

Innovation Solution

A high-speed automated insert feeding system that loads multiple trays of inserts without operator intervention, featuring a tray loading station, tray opening station, transfer shuttle, insert feeder magazine, and picking mechanism, which coordinates to advance and position inserts individually onto a conveying mechanism for seamless delivery to an application station.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Speed

If conventional friction feeders are used to deliver inserts, then the system can operate with simple mechanics, but the system cannot maintain consistent high-speed operation with inserts of various thicknesses

Engineering Contradiction:

Improveoperating speedVSAvoidconsistent operation

Core Design Contradiction:

SpeedVSReliability

Solution Approach 1:

The patent replaces conventional friction-based mechanical feeders with an automated picking mechanism that uses vacuum suction cups to grasp inserts. This substitution eliminates reliance on friction, enabling consistent high-speed operation across inserts of varying thicknesses while maintaining reliable pickup and delivery.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system employs sensors to automatically detect insert presence and thickness variations, then self-adjusts the picking mechanism parameters without operator intervention. This self-service capability ensures consistent high-speed operation across different insert types while eliminating the need for manual calibration.

Inventive Principle:

Principle #25Self-service

2Extent of automation

If operators manually open and load insert trays, then the system can handle various tray types, but the system requires constant operator intervention and cannot achieve high-speed automated operation

Engineering Contradiction:

Improveautomation levelVSAvoidoperator intervention requirement

Core Design Contradiction:

Extent of automationVSEase of operation

Solution Approach 1:

The system automatically performs tray opening and insert loading operations without requiring operators to manually prepare trays. The automated mechanism opens trays and loads inserts in advance, eliminating constant operator intervention while maintaining the ability to handle various tray types through adaptive opening mechanisms.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The automated picking mechanism is designed with adjustable parameters and adaptive grippers that can handle multiple tray types and insert configurations. This universal design enables high-speed automated operation across different tray formats without requiring operator reconfiguration or manual intervention.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Shape

If insert waterfalls are used for orientation transition, then the system can change insert orientation, but the system loses containment of inserts during the transition

Engineering Contradiction:

Improveinsert orientationVSAvoidinsert containment

Core Design Contradiction:

ShapeVSReliability

Solution Approach 1:

The patent replaces the mechanical waterfall orientation system with a controlled picking mechanism that uses vacuum suction to maintain insert containment during orientation transitions. The vacuum grip prevents inserts from falling or becoming misaligned, ensuring reliable containment while achieving the required orientation changes for proper insertion.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Productivity

If conventional packaging systems are used, then the system structure can be simple, but the system requires constant operator observation and loading

Engineering Contradiction:

Improveoperational efficiencyVSAvoidsystem complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The system incorporates sensors and automated control mechanisms that enable self-monitoring and self-loading operations. The picking mechanism automatically detects insert availability, adjusts pickup parameters, and maintains continuous operation without operator observation or intervention, significantly improving productivity while the added complexity is managed through integrated control systems.

Inventive Principle:

Principle #25Self-service

Data Source

PatentUS11873181B2High speed automated feeding system and methods of using the same

Publication Date: 2024.01.16 SERPA PACKAGING SOLUTIONS LLC

AI summary

Disclosed is an automated insert feeding system and related methods, capable of removing bulk-packaged items from a tray or other package, and separating the bulk-packaged items individually for distribution into individual packages in high speed reliable fashion. The disclosed systems can also be loaded with multiple packages of the pre-packaged items for automatic feeding into the system which allows human operators to load several packages and allow the system to work unattended, thereby reducing man-hours spend on the process.