Filling Machine Guide Device for Glass and Plastic Containers
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Solution Overview
Problem
Conventional filling machines are not versatile enough to handle both glass and plastic containers, often causing damage to plastic containers and resulting in liquid waste due to mechanical issues with shutter operation and limited liquid level adjustment, leading to increased production downtimes and costs.
Innovation Solution
A filling machine with a rotary turntable and valve assemblies that include a guide device with a gripper capable of engaging both glass and plastic containers, along with a logic control unit to manage actuation means for precise container handling and liquid level adjustment, allowing for flexible operation with various container formats and temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If hydraulic cylinders raise support plates to open shutters by exerting considerable force, then the shutter opening function is achieved, but plastic containers are crushed and damaged
Solution Approach 1:
The force application is segmented into two independent stages: (1) a lifting mechanism with fingers that gently raises the container to sealing position, and (2) a separate actuating mechanism that opens the shutter. This segmentation allows the lifting force to be minimal (only enough for positioning) while the shutter opening force is applied independently through the movable portion of the supply duct, eliminating the contradiction between sufficient shutter opening force and container protection.
Solution Approach 2:
The lifting fingers act as an intermediary between the support plate and the container, providing a gentle lifting action that positions the container without applying crushing force. This intermediary mechanism decouples the container lifting function from the shutter opening function, allowing the shutter to be opened by the movable portion of the supply duct without the container bearing the full opening force.
2Ease of operation
If mechanical opening of shutter relies on container thrust, then shutter can be opened, but shutter cannot be closed until container is lowered causing liquid waste
Solution Approach 1:
The system uses the container's presence and positioning to automatically trigger shutter opening through the movable portion of the supply duct, which is actuated by the container's engagement. Simultaneously, the shutter closing is automatically controlled by the logic control unit based on container detection, eliminating the need for manual intervention and preventing liquid waste by ensuring the shutter is closed whenever the container is not properly positioned.
Solution Approach 2:
The logic control unit receives feedback from container detection sensors and automatically controls the shutter actuating mechanism. When a container is detected in the correct position, the shutter is opened; when no container is present or the container is improperly positioned, the shutter remains closed. This feedback control prevents liquid waste by ensuring the shutter is only open when a container is ready to be filled.
3Manufacturing precision
If tubular body for level adjustment is manually actuated, then liquid level can be adjusted, but production downtime increases
Solution Approach 1:
The manual mechanical adjustment of the tubular body for level control is replaced with an automated actuating mechanism controlled by the logic control unit. This mechanism can be remotely or automatically adjusted without stopping production, allowing liquid level precision to be maintained while eliminating the production downtime associated with manual adjustment during format changes.
Solution Approach 2:
The liquid level adjustment mechanism is made dynamically adjustable during operation rather than requiring static manual adjustment. The logic control unit can modify the position of the tubular body or the air return tube extension to adapt to different container formats and liquid levels without halting production, transforming a static manual adjustment system into a dynamic automated control system.
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 efficient and reliable filling of both glass and plastic containers with a wide range of formats, reducing damage and waste, and simplifying the production process while minimizing production downtimes and costs.
Implementation Method 1
each support plate of the containers is raised, for example by means of a hydraulic cylinder
Implementation Method 2
During the filling of the container, the air present in the latter is evacuated by means of the air return tube
Data Source
Figure 1
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AI summary
Machine for filling containers with liquids, which comprises a plurality of valve assemblies (12), each provided with a supply duct (14) for the inflow of liquid in containers (2), an air return tube (17) and a shutter (18) placed to intercept the supply duct (14). A guide device (19), equipped with an engagement body (20), and movable between a lowered position and a raised position is provided. The filling machine also comprises: first actuation means (22) that can be actuated to vertically move the support plates (21) of the containers (2) between a lower position and an upper position; second actuation means (23) that can be actuated to act on the guide device (19) in order to move the latter between the lowered position and the raised position. A logic control unit, adapted to control the actuation of the first actuation means (22) and the second actuation means (23) is provided respectively in order to move the support plates (21) between their lower position and their upper position, and in order to move the guide devices (19) between their lowered position and their raised position. By actuating the first actuation means (22), the support plates (21) are moved for associating the valve assemblies (12) with containers (2) made of glass rested on the plates (21); by actuating the second actuation means (23), the guide devices (19) are moved for associating corresponding valve assemblies (12) with containers (2) typically made of plastic retained by the engagement body (20) of the guide devices (19).