Capsule Filling Machine Sequential Weighing System
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Solution Overview
Problem
Current total weight checking systems for capsules filled with pharmaceutical products are imprecise due to variations in empty capsule weights, especially in microdosages, leading to inaccuracies in net weight calculations and inability to identify malfunctioning dosators effectively.
Innovation Solution
A total weight checking system that includes a conveying mechanism to accurately and sequentially transfer filled capsules to a weighing apparatus, using electronic scales with load cells, while maintaining the filling machine's operation, ensuring precise identification and traceability of each capsule, and enabling separate speed control for the filling and weighing processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If total weight checking is performed on all filled capsules using electronic scales with load cells, then measurement precision is improved, but productivity decreases due to the time required for weighing each capsule individually
Solution Approach 1:
The system performs preliminary actions by pre-weighing empty capsules and storing their weights in memory before the filling process. This allows the net weight calculation to be performed quickly using pre-stored tare weights, reducing the time required at the weighing station and enabling faster overall processing while maintaining precision.
Solution Approach 2:
The patent replaces traditional mechanical weighing systems that physically handle and position capsules on scales with an optical identification system using cameras and image processing. This substitution eliminates mechanical transfer mechanisms and positioning requirements, significantly reducing weighing time while maintaining measurement precision through optical capture and digital analysis.
2Device complexity
If empty capsule weight variations are not compensated for, then device complexity is reduced, but measurement precision deteriorates due to the influence of empty capsule weight on net weight calculation
Solution Approach 1:
The system implements feedback by continuously measuring the actual weight of each empty capsule, storing this information in memory, and using it to calculate the net weight of filled capsules. This feedback mechanism compensates for variations in empty capsule weights, ensuring high measurement precision without requiring complex mechanical adjustments or calibration systems.
Solution Approach 2:
The patent performs preliminary weighing of empty capsules and stores their weights in memory before the filling process. This pre-measurement approach allows the system to compensate for empty capsule weight variations during net weight calculation, improving measurement precision while keeping the device complexity low by using simple memory storage and calculation operations.
3Device complexity
If capsules are accumulated in a random manner in the tank and transferred randomly to the weighing unit, then device complexity is reduced, but loss of information occurs making it impossible to associate gross weight with corresponding tare weight
Solution Approach 1:
The patent replaces mechanical capsule identification and tracking systems with an optical identification system using cameras and image processing. This substitution allows the system to capture, store, and process capsule identification information digitally, enabling accurate association between empty and filled capsule weights without complex mechanical tracking mechanisms.
Solution Approach 2:
The system implements feedback by using optical identification to track each capsule through the process, storing identification information in memory, and using this information to correctly associate the weight of the empty capsule with the weight of the filled capsule. This ensures accurate net weight calculation while maintaining simple capsule transfer mechanics.
4Productivity
If the weighing apparatus operates at the same speed as the filling machine, then productivity is maintained, but reliability decreases when the weighing apparatus requires downtime for maintenance or calibration
Solution Approach 1:
The system performs preliminary weighing of empty capsules and stores their weights in memory before the filling process. This pre-measurement approach allows the weighing apparatus to operate independently at its own speed, decoupling it from the filling machine speed. The stored tare weights can be used during filling operations, allowing maintenance or calibration of the weighing apparatus without stopping the filling machine, thus maintaining productivity while improving reliability.
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 system ensures precise and real-time weight measurement of each capsule, maintaining productivity by allowing the filling machine to operate during weighing apparatus downtime, and enables accurate identification of malfunctioning dosators, ensuring all capsules are checked without losing production efficiency.
Implementation Method 1
electronic scales with load cells
Implementation Method 2
load cells on which the capsules have to be positioned
Data Source
Figure 1
Figure 2
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AI summary
A total weight checking system and method for capsules (100) filled with product comprises a filling machine (2) filling the capsules (100) according to a defined filling order, a weighing apparatus (3) weighing all the aforesaid capsules (100) and transferring means (4) transferring said capsules (100) from the filling machine (2) to the weighing apparatus (3), wherein the transferring means (4) comprises removing means (21) and conveying means (5), the removing means (21) being suitable for removing the capsules (100) from the filling machine (2) and for transferring the capsules to the conveying means (5) according to said defined filling order, the conveying means (5) being suitable for housing and accumulating a plurality of capsules (100) according to said defined filling order and transferring the capsules (100) to the weighing apparatus (3) according to said defined filling order.