Weight Consolidation Device Using Single Scale Feedback
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Solution Overview
Problem
Existing methods for consolidating items into packages of a pre-defined target weight are inefficient due to inaccuracies in weighing and random item placement, leading to significant deviations and increased costs, as well as limitations in item assignment and additional process steps.
Innovation Solution
A method where containers are filled with n-1 items, weighed, and the difference calculated to determine the precise weight of the last item needed to reach the target weight, using an adjustable portioning and cutting unit to cut the last item from a larger piece, ensuring accurate weight consolidation with minimal inaccuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If multiple scales are used to weigh individual items and containers, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The patent combines the weighing function into a single scale that measures the total weight of items already placed in a container. This merges multiple weighing operations (individual items + container) into one consolidated measurement, reducing device complexity while maintaining the ability to achieve target weight through iterative addition of items
2Manufacturing precision
If items are assigned to containers based on weight criteria, then manufacturing precision is improved, but productivity decreases due to item separation
Solution Approach 1:
Instead of pre-assigning items to containers based on predicted weight compatibility (which causes blocking and separation), the patent inverts the approach by continuously adding items to a container and only separating when the target weight is reached or exceeded. This eliminates the blocking problem and improves productivity while maintaining weight precision
3Ease of operation
If items are deposited in random order into containers, then ease of operation is improved, but manufacturing precision worsens due to weight deviation
Solution Approach 1:
The patent implements feedback control by measuring the total weight of items in the container and using this information to determine whether to continue adding items or to stop. This feedback mechanism ensures that random item deposition does not compromise weight precision, as the process dynamically adjusts based on actual weight measurements
4Manufacturing precision
If manual weighing and combining is used, then manufacturing precision is improved, but productivity decreases and loss of time increases
Solution Approach 1:
The system performs automated item addition and weight monitoring, eliminating the need for manual weighing and combining operations. The scale provides automatic feedback on total weight, and the system autonomously determines when to stop adding items, thereby maintaining precision while dramatically improving productivity and reducing labor requirements
Data Source
AI summary
Proposed are a method and a device for consolidation of a number n of items, whose weight varies within predefined limits, in a container to a single unit with a predefined target weight. For this purpose, n−1 portions are combined and the weight of all of the n−1 portions is determined. Then the difference between the target weight of the n portions on the one hand and the weight of the n−1 portions on the other is determined. Ultimately, an nth portion with a precise weight is cut-off from a piece, where the weight equals the weight of the nth portion of the difference. For this purpose, the device is provided with a first and a second insertion station, a scale, a computer, and a portioning and cutting device.