Concentric Split Timing Screw for Vial Packing
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Solution Overview
Problem
Existing vial headspace inspection machines face challenges in closely packing vials due to interference between timing screws and reference vials, leading to instability and potential collisions, which are not adequately addressed by current single or multiple screw systems.
Innovation Solution
A concentric shaft split timing screw system with two independently drivable screw segments, where one segment is rotatable within the other, allowing for synchronized or differential rotation to create voids and prevent interference, enabling closer vial packing without the need for a flare.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single timing screw is used to feed vials to the pre-inspection starwheel, then the device complexity is low, but the productivity is limited due to the inability to closely pack vials without causing collisions with reference vials
Solution Approach 1:
The timing screw is divided into two separate segments: a first timing screw segment and a second timing screw segment. Each segment can be independently controlled and positioned, allowing the system to achieve closer vial packing without the limitations of a single continuous screw. The segmentation enables the first segment to feed vials while the second segment manages the transition to the starwheel, preventing collisions with reference vials.
Solution Approach 2:
The first timing screw segment is positioned within the bore of the second timing screw segment, creating a nested configuration. This nesting allows both segments to occupy the same spatial envelope, reducing overall device complexity while enabling independent control of each segment. The inner segment can rotate independently within the outer segment's bore, providing the necessary degrees of freedom for high-density vial feeding.
2Object-affected harmful factors
If the timing screw diameter is increased with a flare at the end to push vials into pockets, then the harmful factor of vial interference is reduced, but the device complexity increases and vial transport stability deteriorates
Solution Approach 1:
Instead of using a single screw with a complex flared geometry, the system segments the timing screw into two simpler segments. The first segment handles vial feeding with a uniform diameter, while the second segment manages the starwheel interface. This segmentation eliminates the need for flared geometries and associated complexity, while still preventing vial collisions through coordinated segment operation.
Solution Approach 2:
The system employs dynamic control of the two timing screw segments, where each segment can rotate at different speeds and pause at different positions. This dynamic capability allows the segments to coordinate their motion to push vials smoothly into starwheel pockets without requiring static geometric modifications like flares. The independent motor control enables real-time adjustment of segment positions to optimize vial transfer and prevent interference.
3Productivity
If vials are fed as close as possible to maximize productivity, then the productivity is improved, but the reliability decreases due to potential collisions and jams
Solution Approach 1:
The independent motor control of the two timing screw segments enables dynamic adjustment of their rotational speeds and positions. This dynamic control allows the system to maintain maximum vial packing density while preventing collisions through real-time coordination. The first segment can feed vials continuously while the second segment pauses to allow proper timing of vial release into starwheel pockets, ensuring reliable transport even at high feeding rates.
Solution Approach 2:
The system incorporates feedback mechanisms where the position and motion of each timing screw segment are monitored and controlled independently. This feedback enables the control system to adjust segment positions and speeds to prevent vial collisions and jams, maintaining reliability even when vials are packed as closely as possible. The independent control allows real-time corrections to prevent interference between vials or with reference vials.
Data Source
AI summary
A split shaft screw system includes a screw configured to convey an article along a movement path. The screw includes a plurality of threads, each thread having a crest, a root and a pair of sidewalls, wherein the root and pair of sidewalls are configured to capture the article. Provided are a first screw segment connected to a first drive shaft configured to be driven by a first motor, and a second screw segment immediately adjacent to the first screw segment and connected to a second drive shaft concentric to the first drive shaft, the second drive shaft configured to be driven by a second motor independently of the driving of the first screw segment.