Variable-Pitch Transfer Line for Boxing Buffer Emptying
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing boxing systems face inefficiencies due to buffer saturation when the boxing machine throughput exceeds the production machine throughput, leading to temporary stops or slowdowns that reduce system efficiency.
Innovation Solution
A system and method that dynamically adjusts product spacing on the transfer line to create empty spaces, allowing periodic emptying of the buffer without stopping or slowing the production machine, using conveyors with variable speeds and manipulators to insert products from the buffer into these spaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the boxing machine operates at high throughput to improve productivity, then the buffer reaches saturation state more quickly, but the production machine must slow down or stop to empty the buffer, reducing system efficiency
Solution Approach 1:
The system implements periodic emptying of the buffer by creating intermittent empty spaces on the transfer line. A manipulator periodically removes products from the buffer and places them in empty spaces on the transfer line, allowing the buffer to be emptied without stopping the production machine. This periodic action maintains high throughput while preventing buffer saturation.
Solution Approach 2:
The transfer line acts as an intermediary between the production machine and the boxing machine. By dynamically creating empty spaces on the transfer line and using a manipulator to move products between the buffer and transfer line, the system mediates the throughput difference between the two machines, allowing the production machine to run continuously at high speed while the boxing machine processes products at its own pace.
2Reliability
If the production machine slows down to empty the buffer, then buffer saturation is prevented, but system efficiency is reduced due to loss of production capacity
Solution Approach 1:
The system performs preliminary action by creating empty spaces on the transfer line before the buffer becomes saturated. The manipulator proactively moves products from the buffer to the transfer line's empty spaces, preventing buffer saturation before it occurs. This allows the production machine to maintain high throughput without being forced to slow down.
Solution Approach 2:
The system dynamically adjusts product spacing on the transfer line by varying the pitch between products. This dynamic adjustment creates empty spaces that can be filled from the buffer, allowing the system to adapt to throughput variations and maintain continuous production without buffer saturation or production stoppages.
3Quantity of substance
If traditional buffering systems are used to handle throughput differences, then product accumulation is possible, but the buffer must be periodically emptied by slowing down the production machine, causing efficiency loss
Solution Approach 1:
The system replaces the traditional mechanical approach of slowing down the production machine to empty the buffer with an automated manipulator system. The manipulator uses robotic or automated mechanisms to remove products from the buffer and place them on the transfer line, substituting the mechanical coupling between production machine speed and buffer emptying with an automated handling system that operates independently.
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
A system (10) for boxing products (P), comprising: - a transfer line (20) configured to transfer products (P) from a product output section (14) of a production machine (12) to a product input section (18) of a boxing machine (16), and - means for varying the pitch (X) between products (P) on the transfer line (20) so as to form empty spaces (ES) having respective lengths (L') in the transport direction (A) equal to or greater than the length (L) of said products.