Aseptic Capping Machine Magnetic Torque Control
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Solution Overview
Problem
Existing capping machines for applying threaded capsules in aseptic or ultraclean conditions face challenges with maintaining sterile conditions due to large machine sizes, rapid wear of elastomeric gaskets, and high costs associated with labyrinth seals and additional sealing elements, leading to potential contamination and increased costs.
Innovation Solution
A capping machine design featuring a fixed annular channel filled with sterile liquid and a coaxial annular element that rotates within the channel, combined with a torque control head that minimizes the number of seals and gaskets required, using a magnetic clutch and bellows elements for effective sealing and torque control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If elastomeric gaskets are used to seal between rotating and fixed parts, then the seal is effective, but the gaskets wear rapidly due to sliding friction and machining tolerances
Solution Approach 1:
The patent replaces the mechanical sliding contact system (gaskets sliding on metallic surfaces) with a magnetic coupling system. The magnetic clutch transmits torque through magnetic fields between the rotating drum and fixed housing without physical contact, eliminating wear from friction. The gaskets are eliminated entirely from the torque transmission path, resolving the contradiction between seal effectiveness and service life.
Solution Approach 2:
The patent introduces magnetic fields as an intermediary to transmit torque between the rotating and fixed parts. The magnetic clutch acts as a mediator that couples the drum to the driving shaft without direct mechanical contact, allowing torque transmission while eliminating the wear problem associated with gasket sliding contacts.
2Duration of action of stationary object
If labyrinth seals are used to reduce gasket wear, then wear is eliminated, but the seal quality depends on small distances between moving parts which are difficult and expensive to achieve in large machines
Solution Approach 1:
The patent replaces the labyrinth seal mechanical system with a magnetic coupling system. Instead of relying on precise mechanical clearances between labyrinth teeth, the magnetic clutch transmits torque through magnetic fields that are not sensitive to the same dimensional tolerances, greatly simplifying manufacturing of large machine components.
Solution Approach 2:
The patent changes the fundamental parameter of torque transmission from mechanical contact force to magnetic field interaction. This parameter change allows for larger tolerances and distances between components while maintaining effective coupling, making the system suitable for large-scale manufacturing where tight tolerances are costly.
3Reliability
If labyrinth seals are used for air exchange, then sealing is achieved, but greater flow of sterile air is required leading to higher costs and risk of lack of isolation
Solution Approach 1:
The patent replaces the labyrinth seal air barrier with a magnetic coupling system that completely isolates the sterile and non-sterile sides. The magnetic clutch allows torque transmission through the isolation barrier without creating air exchange pathways, eliminating the need for high sterile air flow rates and associated costs.
4Adaptability or versatility
If additional sealing elements like bellows are added to accommodate translational motion, then sealing is maintained, but the device complexity and costs increase
Solution Approach 1:
The patent replaces complex mechanical sealing systems (bellows, multiple gaskets) with a magnetic coupling system. The magnetic clutch can accommodate both rotational and translational motions while maintaining magnetic coupling integrity, eliminating the need for additional sealing elements and reducing overall system complexity.
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
This design reduces the number of seals and gaskets needed, minimizes contamination risks, and lowers maintenance costs while maintaining effective sterile conditions, allowing for efficient capping operations in aseptic environments.
Implementation Method 1
a fixed annular channel partly filled with a sterile liquid in which a coaxial annular element associated to the rotating part is sliding in a rotary manner
Implementation Method 2
using a magnetic clutch and bellows elements for effective sealing and torque control
Data Source
Figure 1
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AI summary
There is provided a capping machine (1) comprising a protected area (30) from impurities in which containers (3) pass, an unprotected area (31) divided from the protected area (30) by a parting wall (22), and at least one operating unit (4) including: a container support element (6) arranged in the protected area (30), an operating head (6) also arranged in the protected area (30) and configured to apply one capsule (2) on the relative container (3); a motor assembly (10) arranged in the unprotected area (31) and configured to drive motion of the operating head (7) along and/or around a vertical axis (B); a torque control head (11) interposed between the motor assembly (10) and the operating head (7); and an annular bellows element (57, 70) arranged coaxially with the vertical axis (B) and within the protected area (30) and having one axial end (58, 70a) adjacent to the parting wall (22) and one opposite axial end (59, 70b) crossed in a sealed manner by an output shaft (18) of the torque control head (11); the torque control head (11) is arranged above the parting wall (22) in the unprotected area (31) and the output shaft (18) crosses said opening (25) and the entire bellows element (57, 70).