Capping Torque Adjustment via Reopening and Sensor Feedback
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Solution Overview
Problem
Existing methods for setting the final closing torque of screw caps on containers require manual measurement by trained personnel, leading to inaccurate and time-consuming adjustments, which are not reproducible and increase costs.
Innovation Solution
A method that uses mechanical adjustments to set the closing torque of screwing units, utilizing sensors and mathematical models to record and optimize torques, speeds, and angles, allowing for precise control of capping units to achieve the desired opening torque, eliminating the need for manual personnel and improving accuracy and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual measurement and adjustment by trained personnel is used, then the closing torque can be set, but the adjustment is time-consuming and inaccurate
Solution Approach 1:
The patent replaces manual mechanical measurement with an automated system using sensors (torque sensor, speed sensor) and electronic control units. The torque sensor measures closing torque electronically, and the control unit processes this data to determine opening torque, eliminating the need for manual measurement by trained personnel and significantly improving both accuracy and speed of adjustment.
Solution Approach 2:
The system performs self-adjustment by automatically measuring closing torque, calculating the corresponding opening torque using predetermined relationships, and adjusting the closing unit parameters without requiring external trained personnel. This self-service capability eliminates time loss associated with manual adjustment while maintaining high measurement precision.
2Reliability
If manual adjustment is performed, then torque settings can be made, but results are not reproducible and costs increase
Solution Approach 1:
The patent implements a feedback mechanism where the torque sensor continuously measures closing torque, the control unit calculates the corresponding opening torque based on predetermined relationships, and the system adjusts the closing unit parameters accordingly. This closed-loop feedback ensures reproducible results by automatically compensating for variations and eliminating human error in manual adjustment processes.
Solution Approach 2:
By replacing manual adjustment with an automated sensor-based system, the patent eliminates variability introduced by different trained personnel, ensuring consistent and reproducible torque settings across all adjustments while reducing long-term costs through automation.
3Productivity
If multiple screwing units are adjusted manually, then each unit can be set, but the process is slow and labor-intensive
Solution Approach 1:
The patent employs a universal adjustment system with torque sensors and control units that can be applied to multiple screwing units using the same thread geometry. The system measures closing torque for each unit, calculates the appropriate opening torque using predetermined relationships, and automatically adjusts each unit's parameters, enabling rapid adjustment of multiple units without proportionally increasing system complexity.
Solution Approach 2:
Each screwing unit performs self-adjustment through the automated system, measuring its own closing torque and adjusting its parameters independently based on predetermined relationships. This self-service capability dramatically increases productivity when adjusting multiple units, as each unit can be adjusted quickly and automatically without requiring manual intervention for each individual unit.
Data Source
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AI summary
The invention relates to a method for determining the cap torque required for capping bottles or the like containers with screw caps, using a motor-driven capping unit of a capping machine. According to said method, at least one cap of a previously capped container is reopened in a phase of adjustment, the opening torque required for said reopening being determined as the corrective value and the subsequent capping of the container being carried out by the capping unit with a final cap torque that takes into consideration this corrective value.