Container Transport Sectioning to Prevent Changeover Mixing
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Solution Overview
Problem
Current container treatment systems experience significant production losses and downtime when switching from one type of container to another, due to the need for manual intervention and the risk of mixing different container types during the changeover process, leading to inefficiencies and delays.
Innovation Solution
A method and device that employs a separating device between transport sections to prevent mixing of container types by activating it only when the first section is empty of type A containers, allowing type B containers to be conveyed in without mixing, thus enabling immediate production start-ups and minimizing downtime.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separating device is activated to prevent mixing of container types during changeover, then container type mixing is prevented, but system complexity increases
Solution Approach 1:
The transport device is segmented into multiple transport sections (first transport section and second transport section) that can be independently controlled. The separating device divides the continuous transport flow into separable segments, allowing type A containers to be transported through the first section while type B containers are held in the second section, preventing mixing without requiring complete system shutdown
Solution Approach 2:
The separating device acts as an intermediary element between the first and second transport sections. It mediates the transition between different container types by creating a controlled separation point where type A containers can exit the first section while type B containers are prevented from entering it, thus preventing mixing while maintaining continuous operation
2Reliability
If the first transport section is emptied of type A containers before starting production of type B containers, then mixing is prevented, but production time is lost
Solution Approach 1:
The system performs preliminary emptying of type A containers from the first transport section before the changeover to type B containers is completed. By preparing the separation state in advance and allowing type B containers to be positioned in the second section while the first section is still being emptied, the system minimizes idle time while ensuring no mixing occurs
Solution Approach 2:
The transport device maintains continuous operation during changeover by keeping the second transport section active and ready to receive type B containers while the first section is being emptied. The separating device enables overlapping operations where emptying of type A and preparation for type B occur simultaneously in different sections, eliminating complete shutdown and maintaining continuous useful action
3Reliability
If the separating device is activated early to prevent mixing, then container type mixing is prevented, but type B containers cannot be conveyed into the first section
Solution Approach 1:
The separating device is dynamically controlled based on the real-time state of the transport sections. It is activated at the precise moment when the first transport section has been emptied of type A containers and the last type A container has been detected. This dynamic timing ensures the separation is applied only when necessary, allowing type B containers to enter the first section without restriction during the transition period
Data Source
AI summary
A method and device for treating containers with at least two container treatment machines, between which a transport device for transporting the containers is arranged, where the transport device is divided into several transport sections, where the flow of containers is changed from containers of type A to containers of type B, where a separating device is activated once the first transport section has run empty of containers of type A, where containers of the type B are transported into the first transport section and backed up at the separating device, while containers of type A are transported from the second transport section to the second container treatment machine, and where the separating device is deactivated once the second transport section has run empty of containers of the type A, so that the containers of type B are transported through the second transport section to the second container treatment machine.