Automated Cone Packing System with Chilled Head and Air Bursts
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for filling paper cones with loose particles, such as crumbled leaves, result in non-uniform packing, leading to inconsistent weight, burn rate, and air gaps, and manual processes are labor-intensive and prone to errors, while automated systems face issues with clumping and residue buildup.
Innovation Solution
An automated system that includes a packing head with chilled components, air bursts for packing, a cone trimmer for uniform cone formation, and a fluid injection system with controlled flow paths to prevent cavitation, along with a vacuum filtration system and precise folding mechanisms to ensure consistent and uniform filling and sealing of cones.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If mechanical tamping is used to pack leaves into cones, then the leaves are more compacted, but the packing becomes non-uniform with clumps forming and the paper cones may rip
Solution Approach 1:
The packing process is divided into multiple stages: initial vibration packing, followed by controlled air bursts, then gentle mechanical tamping. This segmentation allows each method to contribute optimally without the harmful effects of any single method dominating the process.
Solution Approach 2:
Air bursts are introduced as an intermediary mechanism between vibration packing and mechanical tamping. The air bursts gently pressurize the leaves, preventing clumping and reducing the risk of cone ripping while still achieving uniform packing.
2Ease of manufacture
If vibrations alone are used to fill cones, then the process is simple, but the leaves remain too loose and clumping occurs
Solution Approach 1:
The patent combines multiple packing methods (vibration, air bursts, and gentle mechanical tamping) into a single integrated process. This merging allows the system to achieve both the simplicity of vibration-based filling and the precision of controlled mechanical packing, while the air bursts prevent clumping.
3Adaptability or versatility
If manual filling methods are used, then flexibility is maintained, but labor intensity increases and productivity decreases
Solution Approach 1:
The automated packing system performs all packing operations independently without human intervention. The coordinated sequence of vibration, air bursts, and mechanical tamping is executed automatically, eliminating labor intensity while maintaining consistent packing quality and high productivity.
4Productivity
If automated filling systems are used, then productivity increases, but clumping and residue buildup occur
Solution Approach 1:
Air bursts are applied as a preliminary action during the packing process to prevent clumping before it occurs. The gentle pressurization from air bursts keeps the leaves separated and prevents residue buildup on machine components, allowing automated high-speed filling without the harmful effects of clumping.
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
The system achieves uniform and consistent packing of cones, reducing waste and increasing productivity by preventing clumping and residue issues, ensuring accurate weight and burn rate, and improving the efficiency of the filling and sealing process.
Implementation Method 1
packing head with chilled components
Implementation Method 2
air bursts for packing
Implementation Method 3
vacuum filtration system
Implementation Method 4
fluid injection system with controlled flow paths
Data Source
AI summary
The present apparatus and system relate to a machine and components thereof adapted to fill packages and which may be utilized according to a method. The machine progresses a package via a conveyor through sub-stations, such as a cone trimmer, product conveyor, packing head, folding station, and injection station. The cone trimmer trims the package to a desired length, the product conveyor deposits product into the packing head, the packing head packs the product in the package, the folding station folds the package, and the injecting station injects the package.