Z-Stacking and Wrap Placement for Fragile Product Packaging
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Solution Overview
Problem
Packaging fragile products is challenging due to the risk of damage from pressure exertion.
Innovation Solution
A stacking and wrapping system comprising a Z-stacking subsystem, a pick and place subsystem, and a wrap management subsystem, which uses wrapping pins and feet to secure products with a continuous wrap, ensuring minimal pressure is applied during the stacking process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional stacking methods are used to package fragile products, then productivity is improved, but the products may be damaged by pressure exertion
Solution Approach 1:
A wrap material is introduced as an intermediary element between the stacking mechanism and the fragile products. The wrap is positioned around the products during stacking, allowing the products to be secured without direct pressure from stacking feet or mechanical contacts. This mediator protects the products while enabling efficient stacking operations.
Solution Approach 2:
The stacking system divides the stacking area into multiple zones with separate stacking feet that can operate independently. This segmentation allows products to be stacked in an organized manner with wrap material positioned between layers, reducing concentrated pressure points while maintaining productivity through systematic multi-zone operation.
2Reliability
If wrap material is positioned between each product during stacking, then product protection is improved, but device complexity increases
Solution Approach 1:
The wrap material is prepared and positioned in advance before the stacking process begins. The wrap is laid out on the stacking surface and products are placed onto it during stacking, rather than attempting to position wrap material between each product layer during the stacking operation itself. This preliminary preparation simplifies the stacking mechanism while ensuring product protection.
Solution Approach 2:
The wrap material serves a dual function: it protects the products and simultaneously facilitates the stacking process. As products are stacked onto the wrap, the wrap naturally positions itself between product layers, eliminating the need for separate mechanisms to insert protective material. The system uses the wrap's own presence to achieve both protection and stacking efficiency.
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
Effectively stacks and wraps fragile products like thin cells without causing damage, enabling secure and efficient packaging.
Implementation Method 1
The pick and place subsystem may include a suction head for picking up one of the plurality of products
Data Source
AI summary
A stacking and packing system is for stacking and packing a plurality of products with a wrap. The stacking and packing system includes a Z stacking subsystem, a pick and place subsystem and a wrap management subsystem. The Z stacking subsystem has a stacking zone and is configured to stack the plurality of products and position the wrap between each of the plurality of products to form a plurality of stacked and wrapped product. The pick and place subsystem is configured to place one of the plurality of products onto the stacking zone. The wrap management subsystem is configured to move the wrap to the stacking zone. Preferably, the first and second wrapping pins are spaced from the products. In one example the product is alternating anodes and cathodes and the plurality of stacked and wrapped product is a battery.