Container Filling System Counters for Changeover Optimization
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Solution Overview
Problem
Current container filling systems face inefficiencies during product changes due to mismatched production times for containers and boxes, leading to inaccurate assessments and prolonged changeover times, resulting in time losses and increased operational costs.
Innovation Solution
A plant and method that utilize counting devices to accurately determine the number of containers and boxes in the system, allowing for precise calculation of the necessary boxes to be supplied, enabling quick and efficient changes between product streams by integrating counters at strategic points and using a calculation device to manage the supply of empty boxes and pallets.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If empirical observation is used to assess box transfer needs during product changes, then the system can operate without complex equipment, but the assessment accuracy is insufficient leading to time losses
Solution Approach 1:
The patent replaces manual empirical observation with automated optical measurement systems (cameras, light barriers) and electronic counting devices to accurately determine the number of containers and boxes in the system, eliminating the imprecision of human estimation while maintaining operational simplicity through automated control
Solution Approach 2:
The patent introduces a calculation device as an intermediary that processes data from counting means and automatically determines the optimal number of boxes to transfer, serving as a mediator between raw measurement data and operational decisions, thereby improving accuracy without requiring complex human judgment
2Productivity
If manual coordination is used for product changes, then the system structure remains simple, but the changeover duration is unnecessarily long and varies greatly
Solution Approach 1:
The patent implements feedback loops where counting devices continuously monitor the numbers of containers and boxes, and the calculation device uses this real-time data to dynamically adjust box transfer decisions, ensuring optimal changeover speed while maintaining systematic control rather than ad-hoc manual coordination
Solution Approach 2:
The system performs self-coordination through automated counting and calculation, where the control system independently determines when and how many boxes to transfer without requiring manual intervention, thereby reducing changeover time variability while keeping the control architecture relatively simple
3Reliability
If excess boxes are discharged at production start to prevent blockage, then system blockage is avoided, but the number of boxes transferred is inaccurate and time is lost
Solution Approach 1:
The patent performs preliminary counting of containers and boxes before product changes using automated counting devices, allowing the system to pre-calculate the exact number of boxes needed, thereby avoiding both the blockage risk of excess discharge and the time loss of inaccurate estimation
Solution Approach 2:
The patent replaces manual judgment about box discharge timing and quantity with automated optical sensing and electronic calculation systems that objectively determine the precise number of boxes to transfer, eliminating the trade-off between preventing blockage and minimizing time loss
4Manufacturing precision
If complete system emptying is performed during product changes, then product mixing is prevented, but the changeover time increases significantly
Solution Approach 1:
The patent applies partial action by transferring only the specific number of boxes calculated to be necessary for the new product run, rather than completely emptying the system, thereby achieving sufficient product separation while minimizing changeover time through precise quantitative control
Data Source
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AI summary
The invention relates to an installation and to a method for filling containers, having an empty-container-delivery means, via which crates with empty containers can be fed to the installation, having an unpacker, which removes the containers from the crates, having at least one treatment station in particular for cleaning and filling the containers, having at least one treatment station, in particular a crate washer, for the crates, having a packer, which can be fed the treated containers and the empty crates and is intended for packing the containers into the crates, having a crate diverter, which can feed the crates to the packer, or can eject them from the installation, having a first counting device for determining the number of containers fed to the installation, having a second counting device for determining a number of crates which have been fed to the packer, and having a calculating device, which can calculate, on the basis of signals from the first and second counting devices, how many empty crates still have to be fed for the established number of containers fed.