Dynamic Sealing Jaw Control for Precise Food Package Volume
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Solution Overview
Problem
Existing packaging units struggle to accurately control the volume of food products in sealed packages without stopping the production line, especially for products of varying viscosity and output rates, while also avoiding marks on the packages.
Innovation Solution
A packaging unit with two forming assemblies that use a combination of sliding jaws and hydraulic cylinders to heat-seal and control the volume of packages, along with a processing unit that generates control schemes to adjust the sealing strip distance and channel width based on desired weight or volume, allowing for real-time and precise control of package dimensions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional fixed sealing methods are used, then the packaging process is simple, but the volume control precision is poor
Solution Approach 1:
The sealing system transitions from fixed to dynamic by allowing the sealing members to move relative to each other. The first sealing member is movable along the tube while the second sealing member remains fixed, enabling real-time adjustment of sealing positions to achieve precise volume control for different package sizes and product viscosities.
Solution Approach 2:
The system incorporates feedback control where the movable sealing member's position is adjusted based on detected package volume or weight measurements. This closed-loop control ensures that the desired volume precision is achieved by continuously monitoring and correcting the sealing position.
2Manufacturing precision
If volume control adjustments are made, then the manufacturing precision improves, but the production line must be stopped
Solution Approach 1:
The movable sealing member enables dynamic adjustment of sealing positions during continuous production without stopping the line. The system can adapt to different package volumes and product viscosities in real-time while maintaining continuous operation, thus preserving high productivity.
Solution Approach 2:
The system changes operational parameters (sealing member position, sealing speed, channel width) dynamically during production to accommodate different product requirements. This allows volume control adjustments without production interruptions, maintaining both precision and productivity.
3Reliability
If the sealing pressure is increased to ensure sealing quality, then the sealing reliability improves, but marks are left on the packages
Solution Approach 1:
The sealing system applies different local qualities by using a movable sealing member that can adjust its contact pressure and position locally on the tube. This allows optimized sealing pressure distribution that ensures reliable sealing while minimizing marks on the package surface.
Solution Approach 2:
The movable sealing member enables dynamic adjustment of sealing parameters during the sealing process, allowing the system to achieve reliable sealing with optimized pressure application that prevents marking on the package while maintaining sealing integrity.
4Adaptability or versatility
If the packaging unit handles products of varying viscosity, then the adaptability improves, but the control system complexity increases
Solution Approach 1:
The system adapts to different product viscosities by dynamically changing operational parameters such as sealing member speed, position, and pressure. The processing unit adjusts these parameters based on detected product characteristics, enabling versatile handling of different viscosities without requiring complex mechanical reconfiguration.
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
Enables continuous and precise control of package volume and weight without stopping the production line, accommodating a range of viscosities and output rates, and prevents marks on packages by adjusting the sealing process dynamically.
Implementation Method 1
a heating member, and an elastomeric member for providing mechanical support to grip the tube to the required pressure
Implementation Method 2
an elastomeric member for providing mechanical support to grip the tube to the required pressure
Data Source
AI summary
A method of producing a sealed package of a pourable food product involving feeding a tube of packaging material along an axis; moving a pair of first jaws and a pair of second jaws cyclically and alternately along sealing paths parallel to the axis, and along repositioning paths; moving the jaws, as they travel along the sealing paths, into a closed position in which the sealing members grip the tube and respectively form, at different times, a first and a second seal sealing the tube and defining respective opposite ends of the package; and moving the jaws, as they travel along the respective repositioning paths, into an open position, in which they are detached from the tube; acquiring a desired value of a quantity related to the package weight; and forming the second seal at a distance, which is a function of the value, from the first seal.