Continuous Filter Bag Forming Machine with Defect Rejection
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Solution Overview
Problem
Existing machines for forming filter bags for infusion products operate intermittently, limiting productivity while maintaining high quality.
Innovation Solution
A machine with continuous movement, featuring a rotating carousel and transfer wheel with gripping devices, allows for fast and precise formation of filter bags, including selection and rejection of unsuitable bags, maintaining high flexibility and speed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a machine operates intermittently (stepwise) to form filter bags, then manufacturing precision and quality can be maintained, but productivity is limited
Solution Approach 1:
The patent implements continuous operation of the carousel and gripping units, eliminating intermittent stepwise movement. The carousel rotates continuously while gripping units remain stationary, allowing multiple filter bags to be processed simultaneously in different operational phases, thereby maintaining quality through consistent processing while dramatically increasing productivity through continuous operation
2Productivity
If multiple gripping units operate simultaneously on a continuously rotating carousel, then productivity increases, but device complexity increases
Solution Approach 1:
The system is divided into distinct functional segments: a continuously rotating carousel, stationary gripping units positioned at different angular locations, and separate operational zones for formation, inspection, and collection. This segmentation allows each component to perform its function independently and continuously, increasing productivity while maintaining manageable complexity through modular functional separation
Solution Approach 2:
The carousel serves multiple functions simultaneously: it holds multiple filter bags at different stages of processing, rotates continuously to bring each bag through all operational zones, and coordinates the timing of gripping units. This multi-functionality allows a single component to replace what would otherwise require multiple separate machines or stations, increasing productivity without proportionally increasing overall system complexity
3Productivity
If defective filter bags are rejected at high speed, then productivity is maintained, but measurement precision requirements increase
Solution Approach 1:
The inspection and defect detection processes are performed while the filter bag is still being held by the gripping unit on the rotating carousel, before the bag is transferred to the collection zone. This preliminary action allows sufficient time for accurate inspection at high speed, as the bag remains stationary relative to the inspection station during the critical measurement phase, thereby maintaining both productivity and measurement precision
Data Source
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AI summary
Described is a machine for forming filter bags (1) for infusion products comprising a carousel (2) for continuous rotary movement; a plurality of gripping means (3) positioned along the movement carousel (2) for holding a respective piece of filter material being formed; a plurality of operating stations (4) positioned along the carousel (2), each operating station (4) being configured to operate on the piece of filter material in order to form a filter bag (1); a transfer wheel (5), rotatable continuously about a second axis (5X) of rotation and actuated in a synchronised fashion with the movement carousel (2); the transfer wheel (5) being equipped with a plurality of gripping devices (6) positioned along the transfer wheel (5) and configured to each receive from a corresponding operating station (4) a filter bag (1) and to release the filter bag (1) in a zone (7) for collecting the filter bags (1); a plurality of control devices (8a, 8b, 9), positioned on the transfer wheel (5), and configured for controlling the corresponding plurality of gripping devices (6) between a first operating position for receiving the filter bag (1) from the carousel (2) or for releasing the filter bag (1) in the collection zone (7), and a second operating position for retaining the filter bag (1); a control unit (10) configured for measuring any defect in the filter bags (1) formed in the carousel (2); an auxiliary control device (11) located on the transfer wheel (5) and connected to the control unit (10); the auxiliary device (11) being configured for controlling, selectively, the passage from a second operating retaining position to a first release position on a predetermined gripping device (6) and along the angular stretch of rotation of the transfer wheel (5), at a control signal of the control unit (10) generated in the presence of a defective filter bag (1), in such a way as to release the defective filter bag (1) in a different collecting zone (12).