Capsule Grouping Rotary Unit for Head-Tail Alignment
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Solution Overview
Problem
Existing machines for packaging capsules in multi-capsule packages face challenges in high productivity and excessive rejects due to unsuitable quality characteristics, where a single defective capsule often leads to the rejection of an entire group, and synchronizing the movement of capsules is difficult.
Innovation Solution
A machine and method that utilize two rotary units and conveyor systems to independently rotate and align capsules in a head-tail configuration, allowing for alternating capsule orientation and independent speed control to reduce rejects and maintain high productivity, even with defective capsules.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single defective capsule is rejected, then quality control is improved, but the entire group of capsules is rejected causing excessive waste
Solution Approach 1:
The system segments the capsule handling process into independent rotational units, each capable of processing capsules individually. This allows defective capsules to be identified and rejected without forcing rejection of adjacent capsules, thus improving quality control while reducing waste.
Solution Approach 2:
The invention applies local quality control by enabling independent inspection and rejection of individual capsules rather than treating the entire group uniformly. Each capsule can be evaluated and handled based on its own quality characteristics, preventing unnecessary rejection of good capsules due to a single defect.
2Productivity
If capsule movement means are actuated continuously, then productivity is improved, but synchronization becomes difficult when restarting
Solution Approach 1:
The system employs dynamic actuation where the rotational movement of capsule handling means can be continuously adjusted. The means can be accelerated or decelerated independently to facilitate synchronized restarting without halting productivity, allowing flexible adaptation to operational requirements.
Solution Approach 2:
The invention utilizes periodic rotational action of the capsule handling means, where each rotational cycle can be independently controlled. This periodic motion allows for synchronized restarting at appropriate phases, maintaining continuous productivity while managing synchronization complexity through rhythmic, predictable cycles.
3Quantity of substance
If capsules are positioned in head-tail orientation to save space, then packaging efficiency is improved, but alignment precision becomes more difficult
Solution Approach 1:
The system performs preliminary alignment of capsules in the desired head-tail orientation before they are grouped and packaged. This pre-positioning ensures that capsules are correctly oriented in advance, making the subsequent grouping process simpler and maintaining high alignment precision while achieving space-efficient packaging.
Solution Approach 2:
The invention replaces complex mechanical alignment mechanisms with a controlled rotational system that automatically orients capsules in the correct head-tail configuration. This substitution simplifies the alignment process while maintaining precision through controlled rotational movement rather than complex mechanical positioning.
Data Source
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AI summary
Described is a unit (1) for grouping together and aligning capsules (2) for extraction or infusion products comprising a first rotary unit (6) equipped with first seats (S1) for receiving capsules (2) designed to receive respective capsules (2) from a transport element (4) of a machine (100) for forming capsules (2); a second rotary unit (7) operating in conjunction with the first rotary unit (6) to receive from the latter, in a predetermined transfer region (R2), capsules (2) and equipped with a first rotary element (7A) equipped with respective second seats (S2) receiving capsules (2) and a second rotary element (7B) equipped with respective third seats (S3) for receiving capsules (2), with the first and second rotary elements (7A, 7B) which can be rotated independently in the same direction (W) of rotation for picking up, alternately and in succession, capsules (2) from the first rotary unit (6).