Container Handling Machine Plunger Force Feedback
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Solution Overview
Problem
Existing container handling systems face challenges in reliably and consistently transforming containers subjected to hot fill processes, as deformation operations can be critical and unpredictable, especially for containers that are overfilled or underfilled, leading to potential deformation issues and complications in label application.
Innovation Solution
A container handling machine that includes a carousel system with operative units equipped with a plunger and actuator assembly, which measures the deforming force applied to the container's base to determine if it is correctly filled, allowing for reliable transformation from a first to a second configuration, and enables precise label application by ensuring the container is in the correct final configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a plunger is used to deform the container base from the first to the second configuration, then the container transformation is achieved, but the operation becomes critical and unpredictable for overfilled or underfilled containers
Solution Approach 1:
The system incorporates a force sensor that measures the deforming force applied by the plunger on the container base. This feedback information is used to detect whether the container is correctly filled, as the force required for deformation varies with the container's filling state. The control unit uses this feedback to determine if the container meets the required filling specifications.
Solution Approach 2:
The patent replaces purely mechanical deformation operations with a system that uses force measurement and control. Instead of relying solely on mechanical plunger action, the system uses sensors to measure the deforming force and control units to regulate the process, making the operation more reliable and predictable.
2Device complexity
If the base deformation operation is performed without force measurement, then the process is simpler, but the quality of container transformation cannot be reliably checked
Solution Approach 1:
The force sensor provides real-time feedback on the deforming force applied during the base deformation process. This allows the system to measure and verify the quality of transformation without adding complex measurement systems, using the inherent force data from the actuator assembly.
Solution Approach 2:
The actuator assembly serves dual purposes: it performs the deformation operation and simultaneously provides force measurement data through its integrated sensor. This self-service approach allows the system to measure deformation quality using the same mechanism that performs the deformation, avoiding additional complex measurement equipment.
3Productivity
If containers are subjected to hot fill processes, then the containers can be filled with hot products, but depressive stresses are generated that may cause unwanted deformations
Solution Approach 1:
The system performs a preliminary deformation of the container base from the first configuration (with downward projecting central area) to the second configuration (with retracted central area) before the container is subjected to normal use. This preliminary action pre-stresses the base to counteract the depressive stresses that will be generated during cooling after hot filling, preventing unwanted deformations.
Solution Approach 2:
The plunger applies a preliminary upward force to deform the base in the opposite direction to the future depressive stress. By pre-deforming the base upward before hot filling, the system creates a counteracting effect that compensates for the downward deformation that will occur during cooling, thereby maintaining shape stability.
Data Source
AI summary
The invention relates to a container handling machine (1) having at least one operative unit (18) comprising first support means (21) to support a base (12) of a filled and closed container (3), second support means (24) cooperating with an end (17) of the container (3) opposite the base (12), a plunger (31) selectively moved along its axis (E) to perform a deformation operation on the base (12) of the container (3) from a first swollen configuration to a second inwardly-retracted configuration, and actuator means (35) selectively activated to move the plunger (31) along its axis (E) between a first position, detached from the base (12) of the container (3), and a second position, in which the plunger (31) defines the second configuration of the base (12); the machine (1) further comprises a control unit (41) configured to selectively activate the actuator means (35) for moving the plunger (31) along its axis (E); the second support means (24) are maintained at a constant distance from the first support means (21) during the deformation operation; the control unit (41) comprises measuring means (42) for measuring the maximum deforming force (F) exerted by the plunger (31) on the base (12) of the container (3) during the deformation operation in order to determine whether the container (3) is correctly filled.