Annular Multihead Weigher for High-Speed Chip Packaging
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Solution Overview
Problem
Current multihead weighers face limitations in packaging rate for low-density products like snack chips and potato chips, with rates capped at 110 batches per minute, and are bulky, costly, and complex, with issues of product trapping in bag seals and long 'slug' lengths during packaging.
Innovation Solution
A redesigned multihead weigher with an annular feeder plate and funnel-shaped staging and weigh hoppers that funnel products inwardly and downwardly under gravity, reducing the number of hoppers and electrical control cabinets to enhance packaging speed and accuracy, and minimize physical size and complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If current multihead weighers are used for packaging low-density products, then packaging rate is limited to up to 110 batches per minute, but the patent aims to achieve up to 250 batches per minute
Solution Approach 1:
The hopper system is divided into multiple weigh hoppers arranged in a compact configuration, with each hopper independently weighing and dispensing product. This segmentation allows parallel processing of multiple batches simultaneously, enabling the system to achieve high packaging rates of up to 250 batches per minute while maintaining reliable operation for low-density products
Solution Approach 2:
The patent employs a multi-level vertical arrangement of weigh hoppers and staging hoppers, transitioning from a horizontal to a three-dimensional configuration. This dimensional change maximizes space utilization and allows product to be funneled efficiently through multiple levels, achieving high-speed packaging while accommodating the specific flow requirements of low-density products
2Reliability
If current multihead weighers are used for packaging low-density products, then the 'slug' length is rather long causing product trapping in hermetic seals, but the patent reduces slug length to minimize packaging errors
Solution Approach 1:
The funnel-shaped hopper design pre-shapes and pre-compresses the product batch before it enters the packaging machine. This preliminary action consolidates the product into a compact form with reduced slug length, preventing trailing chips from being trapped in hermetic seals and eliminating packaging errors related to product dispersion
Solution Approach 2:
The patent modifies the physical parameters of the product batch by using funnel-shaped hoppers that change the density and compactness of the slug during the weighing and dispensing process. This parameter change reduces the length of the product slug while maintaining the required batch weight, ensuring clean sealing and accurate packaging
3Area of stationary object
If current multihead weighers are used, then the physical size is excessively large with height of 2.4 metres and footprint of 2 square metres, but the patent reduces footprint by 50% and height by 30%
Solution Approach 1:
The patent transitions from a horizontal spread-out configuration to a vertical multi-level arrangement, stacking weigh hoppers and staging hoppers in three dimensions. This dimensional change reduces the horizontal footprint by 50% while maintaining the packaging capacity of 250 batches per minute by utilizing vertical space more efficiently
Solution Approach 2:
The hopper system is designed with nested arrangements where staging hoppers are positioned above and feed into weigh hoppers below, creating a compact nested structure. This nesting approach minimizes the overall physical envelope of the machine, achieving the reduced footprint and height specifications while preserving full packaging functionality
4Ease of repair
If current multihead weighers are used, then the number of hoppers and electrical control cabinets is large, but the patent reduces the number of parts to simplify maintenance
Solution Approach 1:
The patent consolidates control functions and reduces the number of electrical control cabinets by integrating controls into a centralized system. Additionally, the hopper configuration is optimized to use fewer hoppers through strategic placement and multi-functional design, reducing the overall number of parts that require maintenance and simplifying repair operations
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
The solution achieves packaging rates of up to 250 batches per minute for lightweight products, reduces the footprint and height by 50% and 30% respectively, minimizes product drop time, and simplifies maintenance with fewer parts, potentially reducing packaging errors and costs.
Implementation Method 1
moving the product radially inwardly on the annular feeder plate to a radially inner edge of the annular feeder plate; dispensing the product downwardly under the action of gravity through an opening defined by the radially inner edge of the annular feeder plate
Data Source
AI summary
A multihead weigher that includes a feeder plate for receiving a product supply that has at least one feed outlet at an inner edge of the annular feeder plate. A plurality of staging hoppers is located beneath the outlet of the annular feeder plate. Each staging hopper has a staging inlet and a staging outlet. The staging inlet is located for receiving product from the annular feeder plate. A plurality of weigh hoppers are located beneath the plurality of staging hoppers. Each weigh hopper has an inlet and an outlet. The weigh hopper inlet is located beneath a respective staging outlet; and a collector is located beneath the weigh hoppers for receiving product from the weigh hopper outlets. The collector has a tubular element for receiving a weighed batch of the product from one or more weigh hoppers and the tubular element has a lower dispensing outlet.