Coating Wheel Inlet Grouping for Flexible Container Spacing
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Solution Overview
Problem
Existing container coating systems face challenges in ensuring flexible and cost-effective operation, particularly when reducing the number of coating modules requires a smaller coating wheel diameter, which is not always feasible due to space constraints and involves complex redesigns.
Innovation Solution
The introduction of an inlet wheel and outlet wheel with adjustable grippers and control cams allows for flexible grouping of containers, enabling different spacing between coating modules and groups, allowing for a variable number of coating modules per group while maintaining a constant first division for transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the number of coating modules is reduced, then the operational flexibility and cost-effectiveness are improved, but the coating wheel diameter must be reduced or the modules arranged on a smaller outer circumference, which is not always feasible due to space constraints and component layout requirements
Solution Approach 1:
The coating wheel is divided into multiple coating groups, where each group contains a specific number of coating modules. This segmentation allows the system to maintain a larger wheel diameter while having fewer active coating groups, providing operational flexibility without requiring a smaller wheel. The pitch between modules within a group (first pitch) differs from the pitch between groups (second pitch), enabling independent optimization of each level.
Solution Approach 2:
Different pitch values are applied to different spatial relationships: a first pitch is used for spacing modules within the same coating group, while a second pitch is used for spacing between different coating groups. This local differentiation allows the system to maintain appropriate spacing for module operation while accommodating a reduced number of active groups on a larger wheel diameter.
2Manufacturing precision
If the coating wheel diameter is reduced to ensure even spacing between coating modules, then the spacing between modules is improved, but the redesign of the coating wheel and its components becomes complex and expensive
Solution Approach 1:
The system introduces variable pitch configurations where the first pitch (within groups) and second pitch (between groups) can be independently adjusted. This dynamic pitch arrangement allows the coating wheel to maintain even spacing precision without requiring a complete redesign, as the spacing can be optimized through configuration rather than structural changes.
Solution Approach 2:
Instead of changing the physical dimensions of the coating wheel, the system achieves even spacing by changing the pitch parameters - using a first pitch for intra-group spacing and a second pitch for inter-group spacing. This parameter-based solution avoids complex redesign while maintaining manufacturing precision.
3Stability of the object's composition
If all coating modules are arranged with the same pitch, then the distribution of modules is even, but the system cannot accommodate flexible grouping configurations required for reduced module operations
Solution Approach 1:
The coating modules are segmented into distinct coating groups, with each group containing a specific number of modules. This segmentation enables flexible configuration where different numbers of groups can be activated while maintaining even distribution within each group through the first pitch, and appropriate spacing between groups through the second pitch.
Solution Approach 2:
The system uses asymmetric pitch values - a first pitch for spacing within groups and a second pitch for spacing between groups. This asymmetry allows the maintenance of even distribution within groups while providing the flexibility to activate different numbers of groups, achieving both stability and adaptability.
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 configuration enables flexible and cost-effective operation by allowing for adjustable container grouping and transfer, reducing the need for complex redesigns and maintaining efficient container handling within the coating system.
Implementation Method 1
the corresponding barrier layer is deposited from the plasma
Implementation Method 2
PICVD processes ('Plasma Impulse Chemical Vapor Deposition'), in which layers of silicon oxide are deposited
Data Source
Figure 1
Figure 2
AI summary
The invention relates to a coating system for coating containers (6), in particular beverage containers, comprising a coating wheel (1) and a plurality of coating modules (4) arranged circumferentially one behind the other on the coating wheel (1), each of which has a container holder and a coating unit associated with the container holder, which are configured to coat the containers (6) during rotation of the coating wheel (1), and wherein at least two coating modules (4) arranged one behind the other are combined to form a coating group (5). Within a coating group (5), the coating modules (4) are arranged in a first division (t1), and two coating modules (4) of different coating groups (5) that are immediately adjacent to one another are arranged in a second division (t2), the second division (t2) being larger than the first division (t1).According to the invention, an inlet wheel (7) is directly adjacent to the coating wheel (1), wherein the inlet wheel (7) is configured to group at least two containers (6) together in the first division (t1) during a circular movement and to transfer them to the coating modules (4) of a coating group (5).