Container Carrier Applicator Synchronization Feedback
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Solution Overview
Problem
Conventional container carrier applicating machines face significant downtime due to difficulties in maintaining synchronization between components, requiring shutdown and manual guess-and-test methods for resynchronization, leading to lost production and inefficiency.
Innovation Solution
The introduction of point-of-use feedback devices, such as tri-color LED indicators and chirping alarms, provides direct visual and auditory feedback to operators, allowing for quick and efficient synchronization of machine components, reducing recovery time and maximizing uptime.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If automatic resynchronization is used after clearing product, then synchronization can be restored, but significant downtime accumulates due to shutdown and re-priming requirements
Solution Approach 1:
The patent implements feedback through synchronization indicators that provide real-time visual status information to operators. This allows operators to monitor the synchronization state of machine components and make informed decisions about when intervention is needed, reducing unnecessary shutdowns and optimizing the resynchronization process.
Solution Approach 2:
The system enables operators to perform self-diagnosis and self-correction of synchronization issues through the visual feedback provided by the indicators. Operators can identify misalignment conditions and manually adjust components without requiring complex diagnostic procedures or system shutdowns, thereby reducing downtime while maintaining synchronization reliability.
2Loss of time
If manual resynchronization methods are used, then downtime is reduced, but the process becomes guess and test based rather than precise
Solution Approach 1:
The synchronization indicators provide precise visual feedback about the alignment state of machine components, replacing guess-and-test methods with observation-based adjustment. Operators can see exactly where misalignment occurs and make targeted corrections, achieving both rapid downtime reduction and high synchronization accuracy simultaneously.
Solution Approach 2:
The patent uses color-changing indicators to communicate synchronization status visually. Different colors indicate different levels of alignment, allowing operators to quickly identify precise misalignment conditions and adjust components accordingly. This visual coding system provides both speed and precision in the resynchronization process.
3Adaptability or versatility
If multiple components operate in different axes of rotation, then machine functionality is achieved, but maintaining synchronization between components becomes complex
Solution Approach 1:
The patent divides the synchronization monitoring into separate, independent segments by providing individual synchronization indicators for each critical component. This segmentation allows operators to focus on and adjust each component's alignment independently, reducing the overall complexity of managing multi-axis synchronization while maintaining full machine functionality.
Solution Approach 2:
The synchronization indicators act as intermediaries between the complex multi-axis mechanical system and the operator. These indicators translate complex synchronization relationships into simple visual signals, making it easier to maintain and adjust components operating in different axes without requiring deep understanding of the underlying mechanical complexity.
Data Source
AI summary
A system and method of identifying and maintaining synchronization of components within a container carrier applicating machine includes connecting a plurality of point of use feedback devices to operative components of the applicating machine and providing visual feedback from the plurality of feedback devices of location of sychronized and or unsynchronized components.