Filling Machine Waste Ejection Using Standardized Web Distance
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Solution Overview
Problem
Existing filling machines waste more packages than necessary due to imprecise determination of waste events, particularly when web splicing occurs, and require labor-intensive manual testing for repeat length changes.
Innovation Solution
Implementing a method and system for package waste management using standardized length measurements, such as millimeters or centimeters, to accurately determine the distance from a waste event to a chute, allowing precise identification of affected packages and reducing manual testing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If individual package tracking based on repeat length is used to determine waste events, then package identification is simplified, but measurement precision deteriorates causing unnecessary package waste
Solution Approach 1:
The patent segments the continuous web measurement into discrete package units by introducing a repeat length parameter. This allows the system to track waste events at the package level rather than continuous web level, simplifying identification while maintaining acceptable precision through the package boundary definition.
Solution Approach 2:
The patent introduces an intermediary calculation layer that converts continuous web position measurements into discrete package identifiers. By using the repeat length as a conversion factor, the system mediates between precise continuous measurement and discrete package tracking, resolving the contradiction between precision and simplicity.
2Manufacturing precision
If repeat length changes require manual testing, then manufacturing precision can be verified, but productivity deteriorates due to time-consuming testing
Solution Approach 1:
The patent performs preliminary calculation of the repeat length parameter during machine setup or parameter changes. By pre-calculating this critical value before production, the system avoids time-consuming manual testing while ensuring manufacturing precision is maintained through accurate mathematical determination of package boundaries.
Solution Approach 2:
The patent replaces manual mechanical testing with automated computational calculation. Instead of physically testing package formation with different repeat lengths, the system uses mathematical calculations based on web speed, sealing frequency, and package dimensions to determine the correct repeat length, dramatically increasing setup speed while maintaining precision.
3Reliability
If conservative waste event determination is used, then reliability of package quality is improved, but loss of substance increases due to unnecessary package waste
Solution Approach 1:
The patent changes the parameter used for waste determination from conservative package-count-based identification to precise position-based identification using continuous web measurement. This allows the system to maintain high reliability by accurately identifying only the specific package affected by waste events, minimizing unnecessary material waste while ensuring quality assurance.
Data Source
AI summary
Methods and apparatus, including computer program products for package waste management in a filling machine. A waste event is detected during operation of the filling machine. The waste event is associated with a waste event detection point in the filling machine and a corresponding web segment position of the packaging material. One or more filled packages to be discarded are identified. The identification is made based on a predetermined distance along a path to be traversed by the packaging material from the waste event detection point to a waste chute of the filling machine. The predetermined distance is expressed in a standardized length measurement format. In response to determining that the web segment position has progressed a distance equaling the predetermined distance, one or more packages formed at or in close proximity to the web segment position are ejected through the waste chute.