Container Handling Machine Deformation Control
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Solution Overview
Problem
Existing container handling machines face challenges in reliably and consistently deforming containers after a hot fill process, leading to unpredictable deformations and potential breakage or incorrect labeling due to factors like overfilling, underfilling, or improper positioning, which affects the container's final configuration and the application of labels.
Innovation Solution
A container handling machine that includes a carousel system with operative units equipped with a deforming plunger and control unit to measure the deforming force and displacement, ensuring correct deformation and filling levels by comparing measured values against thresholds, and using the plunger as a probe to check deformation accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a deforming plunger is used to transform the container base from the first unstable configuration to the second stable configuration, then the containment volume is considerably reduced and depressive stresses are cancelled, but the final configuration becomes unpredictable due to factors like filling level and positioning
Solution Approach 1:
The patent applies preliminary action by performing a first deformation stroke to transform the container base from the first unstable configuration to an intermediate state, then performing a second checking stroke to verify the deformation was successful before proceeding to labeling. This ensures the container is properly deformed and positioned before the labeling operation, eliminating unpredictability in the final configuration.
Solution Approach 2:
The patent implements feedback by using sensor means to detect whether the container base has been correctly deformed to the second stable configuration. The control unit receives signals from these sensors and can adjust the deformation process or reject improperly deformed containers, ensuring consistent and reliable configuration transformation.
2Manufacturing precision
If the container is overfilled or underfilled, then the deforming action produces incorrect or insufficient deformation, but detecting and measuring the filling level and deformation quality requires complex control systems
Solution Approach 1:
The patent applies self-service by using the deforming plunger itself as a probe to check the deformation quality. The same plunger that performs the deformation also serves as the sensing element, eliminating the need for separate complex measurement systems. The plunger's displacement and force characteristics provide feedback on whether the container was properly filled and deformed.
Solution Approach 2:
The patent implements multi-functionality by designing the deforming plunger to serve multiple functions: it deforms the container base from the first to second configuration, and simultaneously acts as a probe to detect deformation quality and filling level. This reduces device complexity while maintaining high manufacturing precision.
3Manufacturing precision
If multiple machines are used for deformation and labeling operations, then each operation can be performed with high precision, but the number of machines and space required increases
Solution Approach 1:
The patent merges the deformation operation and the deformation checking operation into a single integrated machine. The same plunger and operative unit perform both the transformation of the container base and the verification of the deformation quality, eliminating the need for separate machines and reducing space requirements while maintaining precision.
Solution Approach 2:
The patent applies multi-functionality by designing the operative unit to perform multiple functions: deformation of the container base, checking of deformation quality, and preparation for labeling. This consolidation of functions into a single machine improves space efficiency while maintaining high operation precision.
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 machine reliably checks the quality of container deformations and filling levels, ensuring accurate transformation into the desired configuration, reducing deformations and improving label application precision, while also reducing the number of machines and space required in processing plants.
Implementation Method 1
a deforming plunger (31), which is displaceable along its axis (E) with respect to the resting element (21), to act, through opening (30), on base (12) of relative bottle (3) and deform it from the first to the second configuration
Implementation Method 2
measuring means (42) for measuring a physical quantity (I) correlated to the maximum deforming force (F) exerted by each plunger (31) on base (12) of the relative bottle (3) during the deformation operation of the base (12) itself
Implementation Method 3
By effect of the capping operation, the heated air present in the top portion ('head space') of the container expands causing a stress tending to produce a general swelling of the container at the side wall and at the base wall
Implementation Method 4
The following cooling to which the container is subjected, causes, vice versa, a reduction of the volume of air and minimally of the liquid product contained in the container; a depression is therefore created, which tends to pull the side walls and the base wall of the container inwards
Data Source
AI summary
A container handling machine having at least one operative unit is disclosed. The container handling machine includes a plunger configured to selectively move along a longitudinal axis and to deform a base of a container from a first swollen configuration to a second inwardly-retracted configuration, and an actuator configured to selectively move the plunger along the longitudinal axis between a first position, in which the plunger is detached from the base of the container, and a second position, in which the plunger deforms the base to the second configuration. The container handling machine further includes a control unit configured to selectively activate the actuator for producing a first stroke of the plunger along the longitudinal axis between the first position and the second position, in order to deform the base of the container.