Research and Development - Cigarette Switch

Common in the distribution of cigarettes is the need to stamp each pack of cigarettes with the appropriate state tax code based on its destination. This operation of stamping is done after the particular order is picked in the order fulfillment system. Due to the need to change between different state stamps, three stamping machines are required to service two pick lines. The solution Blue Arc developed for this process required the cigarette carts to be diverted to another machine during this stamp changeout. A key challenge in the design of this machine is the fact that the cigarette cartons are oriented “crossways” on the pick belt, meaning the length of the carton is 1.5”. This creates an issue in the need to transition from one belt conveyor to another. It also creates the need to be able to keep the carton perpendicular to flow as it is being plowed to a new lane.

The solution to the first issue was to design belt bridge transitions from the pick conveyor to our conveyor. These two strands of polyurethane belt would carry the carton over the transition gap. A polyurethane belt was also used as the powered face plow to allow the cartons to divert in a controlled method. A variable frequency drive (VFD) would allow a change in speed of the powered face plow belt relative the plastic conveyor belt, which allowed for ultimate control of the carton orientation.