Synchronized Container Recirculation for Multi-Pass Starwheel Lines
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Solution Overview
Problem
Conventional single-pass and two-pass machine arrangements for bottle and can manufacturing require extensive space and resources, with two-pass systems sacrificing throughput due to non-synchronous operations, leading to inefficiencies and increased costs.
Innovation Solution
A system with a recirculation line and synchronized line starwheels that allow multiple recirculations of containers at varying stages of manufacture, reducing the number of machines needed by using a synchronization mechanism to ensure accurate placement and operation of articles through multiple passes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single-pass machine arrangement is used, then the manufacturing process is simple, but the system occupies a large amount of space and requires duplicate machines
Solution Approach 1:
The patent merges multiple processing passes into a single machine line by implementing a recirculation system where containers are processed multiple times through the same starwheels and machines. This consolidation eliminates the need for duplicate machines that would otherwise be required in separate parallel lines, reducing overall system footprint while maintaining processing capability.
Solution Approach 2:
The patent introduces a temporal dimension to the manufacturing process by implementing multi-pass recirculation. Instead of expanding spatially with parallel machine lines, the system expands temporally by having containers circulate through the same physical machines multiple times, effectively transforming a spatial problem into a temporal solution.
2Area of stationary object
If a two-pass recirculation system is used, then the system footprint is reduced, but throughput is sacrificed due to non-synchronous operations
Solution Approach 1:
The patent implements dynamic synchronization mechanisms that adapt the timing and speed of recirculating containers to match the processing cycles of the starwheels. The system dynamically adjusts container flow rates and timing based on real-time machine status, ensuring that containers are available at the correct moments for processing without creating bottlenecks that would reduce throughput.
Solution Approach 2:
The synchronization mechanism incorporates feedback loops that monitor the position and status of containers throughout the recirculation system. This feedback enables real-time adjustments to maintain synchronous operation between container flow and machine processing cycles, preventing jams and collisions while maximizing throughput efficiency.
3Area of stationary object
If multiple recirculations are implemented without synchronization, then space is saved, but collisions and jams occur due to improper container placement
Solution Approach 1:
The synchronization mechanism performs preliminary actions by pre-positioning containers in the recirculation system at appropriate intervals and locations before they reach processing stations. This advance preparation ensures that containers are ready for processing without requiring last-minute adjustments that could cause misalignment, collisions, or jams.
Solution Approach 2:
The patent introduces synchronization mechanisms as intermediary components between the recirculation conveyor and the processing starwheels. These intermediaries buffer and coordinate container flow, absorbing variations and mismatches between container arrival times and machine processing rates, thereby preventing direct collisions and jams at critical interfaces.
Data Source
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AI summary
Systems and methods for performing multiple recirculations of a plurality of articles are disclosed. A system includes a plurality of line starwheels and a recirculation line. The plurality of line starwheels each include a plurality of starwheel pockets thereon. The plurality of starwheel pockets includes a first-pass, a second-pass, and a third-pass starwheel pocket. The recirculation line includes a synchronization mechanism and a plurality of line-pocket sets. Each of the line-pocket sets includes a first and a second line pocket. The line pockets are configured to receive an article from a downstream line starwheel and deposit the article in the proper starwheel pocket of an upstream line starwheel. The synchronization mechanism configured to synchronize the plurality of line-pocket sets to the plurality of starwheel pockets. The first-pass, second-pass, and third-pass starwheel pockets correspond with respective first, second, and third stages of modifying the article.