Packing Machine Component Transponders for Precise Maintenance Tracking
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Solution Overview
Problem
Existing packing machines for cigarettes face challenges in accurately determining the operating hours of format-related components, making precise maintenance scheduling difficult due to inevitable wear and format changes.
Innovation Solution
The implementation of transponders with programmable memory and wireless transmission devices on each component of the packing machine, allowing for precise tracking of component-specific data, including operating life, maintenance history, and configuration parameters, enabling efficient maintenance scheduling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the overall hour meter of the automatic machine is used to determine component operating hours, then maintenance scheduling is simple, but precision is poor for format-related components that are cyclically replaced
Solution Approach 1:
The patent divides the maintenance tracking system into component-level segments. Each component has its own transponder with memory storing individual operating hour data, rather than using a single centralized hour meter for the entire machine. This segmentation allows precise tracking of each component's actual usage, especially format-related components that are cyclically replaced.
Solution Approach 2:
The system implements feedback by having transponders on components communicate their operating hour data to the control unit. The control unit reads and stores this data, creating a feedback loop that continuously updates the maintenance scheduling system with accurate component-level information, enabling precise maintenance timing.
2Measurement precision
If transponders with memory are added to each component for precise tracking, then maintenance scheduling precision improves, but device complexity and cost increase
Solution Approach 1:
Each component serves itself by having an integrated transponder that automatically stores and communicates its own operating hour data. The component's transponder autonomously tracks its usage and provides this information to the control unit without requiring external manual tracking, enabling self-monitoring and simplifying the overall system architecture.
Solution Approach 2:
The patent replaces manual or centralized mechanical hour meter tracking with electronic transponders and wireless communication. This substitution uses electromagnetic fields for data transmission between components and the control unit, eliminating the need for physical connections or complex mechanical tracking systems while reducing implementation costs.
3Adaptability or versatility
If format-related components are cyclically replaced during format changes, then adaptability improves, but accurate tracking of actual hours worked becomes difficult
Solution Approach 1:
The system performs preliminary action by resetting the transponder memory of format-related components when they are replaced during format changes. The control unit detects component replacement and automatically resets the operating hour counter, ensuring that tracking begins fresh for each new component installation. This preliminary reset action maintains accuracy despite cyclic replacement.
Solution Approach 2:
The control unit continuously monitors component status and receives feedback from transponders about operating hours and replacement events. This feedback mechanism allows the system to automatically adjust tracking for format-related components that are cyclically replaced, maintaining precision by detecting when components are swapped and resetting their counters accordingly.
Data Source
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AI summary
An automatic machine (6) for the production or packaging of smoking, sanitary, foodstuff, or pharmaceutical products; the automatic machine (6) has: a processing line (8) along which the products are processed; a plurality of components, which are distributed along the processing line (8) so as to make up the processing line (8); at least one transponder (16), which is mounted on a corresponding component, comprises a programmable memory (17) designed to contain solely a series of data of the component, and comprises a first transmission device (18), which is designed to send and receive the data contained in the programmable memory (17); a second transmission device (20), which is designed to communicate with the first transmission device (18); and a control unit (14), which controls the operation of the automatic machine (6) and is connected to the second transmission device (20). The memory (17) of the transponder (16) contains a univocal identifying code (IDC) of the corresponding component and a record of events of the operating life of the corresponding component. The control unit (14) is designed to change, through the second transmission device (20), the content of the memory (17) of the transponder (16) so as to update the events of the operating life of the corresponding component.