Independent Container Routing for Mixed-Product Filling Lines
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Solution Overview
Problem
High speed container filling systems are inflexible, requiring significant time and cost to change configurations for different container types and fluids, and are unable to efficiently handle various container arrangements and packaging without manual handling, leading to inefficiencies and inaccuracies.
Innovation Solution
A track system with propellable vehicles and unit operation stations that allows for the simultaneous filling and treatment of multiple container types with different fluids, enabling on-demand production and automated routing to optimize container handling and packaging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a high speed container filling system is configured to fill one type of container with one type of fluid, then filling efficiency is improved, but adaptability deteriorates requiring time-consuming reconfiguration for different container types
Solution Approach 1:
The system employs multiple interchangeable nozzle assemblies that can be quickly swapped to accommodate different container types and fluid products. The carrier system is designed with adjustable configurations to handle various container sizes and shapes, allowing a single filling system to perform multiple functions without extensive reconfiguration
Solution Approach 2:
The system incorporates adjustable and reconfigurable components including variable nozzle positions, adjustable carrier configurations, and programmable control systems that can dynamically adapt to different container types and filling requirements, enabling rapid changeover between product lines
2Adaptability or versatility
If the system configuration is changed to accommodate different container types and fluids, then product diversity is improved, but system downtime increases
Solution Approach 1:
Multiple nozzle assemblies are pre-configured for different container types and fluid products, allowing operators to quickly swap between pre-prepared configurations rather than reconfiguring components during changeover. The system maintains ready-to-use nozzle sets that can be rapidly installed
Solution Approach 2:
The filling system is divided into modular, independently replaceable components including nozzle assemblies, carrier sections, and control modules. This segmentation allows specific components to be changed without affecting the entire system, enabling rapid reconfiguration for different products
3Adaptability or versatility
If multiple high speed container systems are employed to provide diverse product lines, then product variety is improved, but system cost and space requirements increase
Solution Approach 1:
A single filling system is designed to handle multiple container types, sizes, and fluid products through interchangeable nozzle assemblies and adjustable carrier configurations, replacing the need for multiple dedicated filling lines and reducing overall system complexity and space requirements
Solution Approach 2:
The system combines multiple filling capabilities into one integrated platform by merging different nozzle types, carrier configurations, and control functions into a unified system that can be reconfigured for various products, consolidating what would traditionally require separate filling lines
4Adaptability or versatility
If manual handling is used to provide different container arrangements and packaging, then packaging flexibility is improved, but accuracy and efficiency deteriorate
Solution Approach 1:
The system incorporates automated container handling and positioning mechanisms that self-adjust to create different packaging arrangements based on programmed instructions, eliminating the need for manual intervention while maintaining high accuracy and consistency in package configuration
Solution Approach 2:
The packaging system uses programmable and adjustable mechanisms that can dynamically reconfigure container arrangements according to different packaging requirements, providing the flexibility previously achieved through manual handling but with automated precision and efficiency
Data Source
AI summary
A system and method for independently routing container-located vehicles to create different finished products are disclosed. The vehicles are independently routable along a track system to deliver the containers to at least one unit operation station. At least some of the vehicles have a unique route associated therewith that is assigned by a control system to facilitate simultaneous production of different finished products.