Filter Bag Packaging Machine Defect Detection and Rejection Control
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Solution Overview
Problem
Existing machines for packaging filter-bags with overwrap envelopes continue to waste overwrapping material and risk damage to components when processing defective bags, as they automatically wrap and attempt to seal all bags, including defective ones, leading to soiling and machine stoppages.
Innovation Solution
An automated machine with a control system that detects defects and switches between wrapping and rejection modes, preventing the unwinding of overwrapping material for defective bags, thus avoiding unnecessary material waste and reducing the risk of damage to machine components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the machine automatically wraps all bags including defective ones, then the wrapping process continues without interruption, but overwrapping material is wasted and machine components are at risk of damage
Solution Approach 1:
The machine performs preliminary defect detection using sensors (optical, mechanical, or other detection devices) before the wrapping station processes the bag. This allows the control system to预先 determine whether a bag is defective and prevent wrapping of defective bags, thereby avoiding material waste while maintaining continuous operation for non-defective bags
Solution Approach 2:
The machine implements a feedback mechanism where detection signals from quality control sensors are transmitted to the control system, which then adjusts the wrapping station's operation accordingly. When a defective bag is detected, the control system receives the signal and prevents the wrapping mechanism from operating on that bag, creating a closed-loop control system that eliminates material waste
2Productivity
If the machine attempts to seal all bags including defective ones, then the sealing mechanism operates continuously, but machine components are at risk of damage and soiling occurs
Solution Approach 1:
The machine performs preliminary defect detection before the bag reaches the sealing station. The detection system (sensors positioned along the production line) identifies defective bags upstream, allowing the control system to prevent the sealing mechanism from operating on defective bags, thereby avoiding component damage and soiling while maintaining continuous operation
Solution Approach 2:
The control system receives detection signals from quality control sensors and uses this feedback to control the sealing mechanism. When a defective bag is detected, the control system receives the signal and prevents the sealing mechanism from operating on that bag, creating a feedback loop that protects machine components while maintaining continuous production
3Productivity
If the machine processes defective bags through all stations, then the production flow is maintained, but soiling occurs and machine stoppages are required
Solution Approach 1:
The machine performs preliminary defect detection at multiple points along the production line (infeed station, before wrapping station, before sealing station) to identify defective bags before they can cause soiling or require machine stoppages. This preliminary action allows defective bags to be identified and excluded from further processing while maintaining continuous production flow for non-defective bags
Solution Approach 2:
The control system receives detection signals from quality control sensors positioned at various stations and uses this feedback to prevent defective bags from proceeding through stations where they could cause soiling. The feedback mechanism enables the machine to maintain continuous production flow for good bags while automatically excluding defective ones, eliminating the need for manual intervention and machine stoppages
Data Source
Figure 1
Figure 2a~2b
Figure 2c~2d
AI summary
Described is a machine (1) for packaging filter-bags (4, 4') each wrapped in a sheet of overwrapping material (F) and containing a respective dose of infusion product, comprising: a rotary carousel (2) equipped with a plurality of grippers (3) each of which is designed to adopt a retaining condition and a release position of a respective bag (4; 4'), the carousel (2) rotates about an axis of rotation (R) in such a way as to cause a movement of each of the grippers (3) along an operating path so that each bag (4; 4') is transported by the gripper (3) along the path; a plurality of stations distributed along the operating path to perform a plurality of operating steps on each bag (4; 4'); and wherein at least one of the stations is a wrapping station (5d) configured to operate, on the bag (4; 4'), according to a wrapping mode, according to which the bag (4; 4') is picked up by the gripper (3), wrapped in a sheet of overwrapping material (F) fed by unwinding means (6), and repositioned in the respective gripper (3); the wrapping station (5d) is configured to operate, on the bag (4; 4'), according to a rejection mode, in accordance with which the unwinding means (6) are deactivated and the respective bag (4; 4') is maintained in position in the respective gripper (3).