Automated Sampling Station for High-Speed Box Filling Lines
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Solution Overview
Problem
Existing filling devices for folding boxes struggle with efficient sampling, particularly in high-speed production environments, as they require manual intervention downstream and can only sample one box at a time upstream, which is not compatible with high-volume production demands.
Innovation Solution
A filling device with a sampling station and recovery station, utilizing a second box conveyor to divert and transfer boxes from the sampling station to the recovery station, allowing for automated sampling and reducing operator intervention by enabling simultaneous sampling and recovery of multiple boxes without disrupting the production flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual sampling is performed downstream of the filling device, then sampling can be done after production, but it is not compatible with high-speed production systems and reduces productivity
Solution Approach 1:
The sampling station diverts boxes from the conveyor belt before they reach the filling device, performing sampling action in advance. This allows quality control to be conducted on diverted samples while the main production line continues at full speed without interruption, resolving the contradiction between sampling capability and production speed
2Extent of automation
If automatic sampling devices are used upstream of the filling device, then sampling is automated, but the device complexity increases and only one box can be sampled at a time
Solution Approach 1:
The sampling function is extracted from the main filling device and implemented as a separate, simple diversion station using basic mechanical elements like a diverting belt and guide rollers. This extraction simplifies the overall system while maintaining automation, as the sampling station operates independently from the complex filling mechanism
Solution Approach 2:
A simple intermediary diverting mechanism is introduced between the folder-gluer output and the filling device. This intermediary sampling station uses basic mechanical components to divert selected boxes onto a separate conveyor path, avoiding the need for complex automated sampling integrated into the main device
3Quantity of substance
If a separate sampling conveyor is added to divert boxes, then multiple boxes can be sampled simultaneously, but the device complexity increases
Solution Approach 1:
The sampling conveyor is merged with the existing main conveyor system, sharing common structural elements like the conveyor frame, drive mechanisms, and control systems. The diverting belt integrates with the main belt structure, allowing multiple boxes to be sampled simultaneously while minimizing additional complexity through shared components
Data Source
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AI summary
The filling device according to the invention comprises a layering station (A), a filling station (B), a first box conveyor (3) designed to convey boxes leaving a folder-gluer (1) and to feed them from said layering station (A) towards said filling station (B) along a feed path (Ta), a sampling station (C), a recovery station (D), a second box conveyor (10) designed to convey boxes fed by the first box conveyor (3) and to transfer them from said sampling station (C) towards said recovery station (D) along a transfer path (Tt).