Bottle Transport System Buffering via Star Wheel Segmentation
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Solution Overview
Problem
Existing transport systems for bottles between blow molding and filling machines cannot continuously convey containers to a buffer line and re-insert them into the conveyor flow, leading to material waste and delays during malfunctions in downstream processes.
Innovation Solution
A transport system with a rotating transfer star wheel and separation star wheels that allows bottles to be buffered during malfunctions, enabling continuous operation of the blow molding machine and efficient re-routing of bottles to the filling machine once the issue is resolved.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single transfer position is used for both buffer feed and buffer discharge, then the transport system structure is simplified, but continuous conveyance to and from the buffer line is not possible
Solution Approach 1:
The transfer star wheel is divided into multiple independent transfer positions (first transfer position for buffer feed, second transfer position for buffer discharge). This segmentation allows each position to perform its specific function independently, enabling continuous conveyance while maintaining system clarity and manageability.
Solution Approach 2:
The system transitions from a single-dimensional transfer point to a multi-dimensional transfer system with multiple positions arranged spatially around the star wheel. This dimensional expansion allows simultaneous or sequential operations of feeding to and discharging from the buffer line without functional conflict.
2Loss of substance
If the blow molding machine stops during downstream malfunctions, then material waste is prevented, but production delays increase
Solution Approach 1:
The buffer line is pre-positioned and ready to receive containers before malfunctions occur. When the downstream filling machine malfunctions, the blow molding machine can continue operating and deposit containers into the pre-ready buffer line, preventing material waste without causing production delays.
Solution Approach 2:
The buffer line acts as an intermediary storage system between the blow molding machine and the filling machine. It mediates the mismatch in operational continuity, allowing the blow molding machine to run continuously while the filling machine undergoes maintenance or repairs.
3Device complexity
If containers are discarded during downstream malfunctions, then system simplicity is maintained, but material loss increases
Solution Approach 1:
Instead of discarding containers during downstream malfunctions, the system recovers them by transferring to the buffer line for temporary storage. When the filling machine is restored, containers are retrieved from the buffer line and continued to the filling process, eliminating material loss while maintaining operational simplicity.
Data Source
AI summary
This present application relates to a transport system for the transport of bottles or similar containers between at least a first machine, for example a blow molding machine for the manufacture of the containers out of plastic, and at least one second machine, for example a filling machine.