Vibrating Conveyor Defect Rejection System
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Solution Overview
Problem
Current pharmaceutical packaging processes result in high waste of good medical products due to the rejection of entire batches when a single defective product is detected, as existing systems lack efficient mechanisms for isolating and removing only the defective items during the filling of tablets in blister packs or bottles.
Innovation Solution
A device comprising an oscillating conveyor with detection and chute systems, along with a diverting device that can be displaced or pivoted to intercept and divert defective products, ensuring safe ejection while maintaining a simple design, and a method that utilizes a camera system and suction device for precise detection and removal of defective products.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a defective product is detected during filling, then quality control is improved, but the entire batch of blister packs or bottles must be discarded, resulting in high waste of good medical products
Solution Approach 1:
The conveying system is divided into multiple independent conveying lanes, each capable of transporting products separately. When a defective product is detected in one lane, only that specific lane's batch is affected, while other lanes continue operating normally, preventing wholesale rejection of entire batches.
Solution Approach 2:
A suction gripper is used to extract and remove individual defective products from the conveying lane immediately after detection. This allows the defective product to be taken out from the continuous flow, enabling subsequent good products in the same lane to continue being filled without discarding the entire batch.
2Loss of substance
If individual defective products are removed using a suction gripper, then waste of good products is reduced, but the device complexity increases due to additional components
Solution Approach 1:
The suction gripper is integrated directly into the conveying lane structure, merging the rejection function with the existing conveying system. This combination reduces the need for separate, standalone rejection mechanisms and simplifies the overall device architecture while maintaining the capability to remove individual defective products.
Solution Approach 2:
The suction gripper is controlled by a control device that automatically activates it when a defective product is detected by the detection device. This automated self-service mechanism eliminates the need for manual intervention and reduces the complexity of control systems while achieving effective rejection of defective products.
3Reliability
If a suction gripper is lowered onto the vibrating conveyor to remove defective products, then individual rejection is achieved, but the structural complexity and operational complexity increase
Solution Approach 1:
The suction gripper is designed to be movable along the conveying lane, allowing it to dynamically position itself at the location where a defective product is detected. This dynamic positioning capability enables the gripper to intercept and remove defective products at optimal points without requiring complex mechanical structures or manual operation.
Solution Approach 2:
The control device receives signals from the detection device and automatically controls the suction gripper's activation and positioning based on real-time detection feedback. This closed-loop feedback system simplifies operation by automating the rejection process, eliminating the need for manual monitoring and intervention while maintaining high reliability in individual product rejection.
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 solution allows for the safe and efficient isolation and removal of individual defective products, preventing the disposal of good products and minimizing waste, while maintaining a structurally simple and reliable operation.
Implementation Method 1
a vibratory conveyor with a plurality of adjacent conveying lanes for transporting the medical products
Implementation Method 2
remove individual products from the vibrating conveyor using a suction gripper lowered from above onto the vibrating conveyor
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The method for transferring medical products (4) comprises transporting medical products (4) on a vibrating conveyor (6) with a plurality of adjacent conveying lanes (7) to a discharge area (8) of the conveying lanes (7) and from there into at least one shaft (14); detecting a defective product (12) in one of the conveying lanes (7); and activating a discharge device (26) for defective products (12), which is arranged near the discharge area (8) of this conveying lane (7), in the event of the detection of a defective product (12), wherein the discharge device (26) is moved or pivoted into an activated position in which it is located in a transport path of the defective product (12).