Filter Production Machine with Suction Pockets and Accordion Folding
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Solution Overview
Problem
The production of tubular elements with a truncated cone shape and a filter at one end is currently carried out manually, resulting in high production costs, limited volume capacity, and variable, often low-quality final products.
Innovation Solution
A manufacturing machine and method are developed to produce filters for tubular elements, featuring an intermittent motion system with rotating drums and pockets that suction and fold wrapping sheets into tubular shapes, allowing for high productivity and quality control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual production methods are used, then production costs are high and quality is variable, but device complexity and productivity are not relevant factors
Solution Approach 1:
The manufacturing machine is divided into multiple functional modules: a wrapping sheet feeding mechanism, a folding mechanism with crease formation elements, a filtering mechanism, and a conveying system. Each module performs a specific operation in the sequence of transforming flat wrapping sheets into tubular elements with filters, enabling complex production through modular functional segmentation.
Solution Approach 2:
The machine performs preliminary actions by pre-forming creases and folds in the wrapping sheet before final tubular assembly, and by pre-positioning filters in the correct orientation and location. This ensures proper formation and alignment of components before the final assembly step, improving production quality and consistency.
2Manufacturing precision
If manual production methods are used, then quality control is difficult, but automation level is low
Solution Approach 1:
The machine incorporates control systems that monitor and adjust the folding, creasing, and filtering operations to maintain consistent product quality. The automated conveying and positioning systems ensure uniform spacing and alignment of tubular elements, providing feedback control for manufacturing precision.
Solution Approach 2:
Manual mechanical operations are replaced with automated mechanical systems that use controlled forces and precise positioning mechanisms. The folding mechanism uses controlled pressure and geometry to create consistent creases, while the conveying system uses controlled motion to maintain uniform spacing, replacing manual variability with automated precision.
3Productivity
If manual production methods are used, then production costs are high, but automation investment is required
Solution Approach 1:
The machine enables continuous production by maintaining uninterrupted flow of wrapping sheets through the folding, creasing, and filtering mechanisms. The automated conveying system keeps materials moving continuously through each stage, eliminating idle time and maximizing hourly production rate without requiring manual intervention.
Solution Approach 2:
The machine optimizes production parameters such as folding speed, crease depth, filter positioning speed, and conveying velocity to achieve high productivity. By controlling these parameters within optimal ranges, the machine maintains high hourly production rates while managing operational costs effectively.
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
The machine achieves high hourly productivity (200-300 tubular elements per minute) while ensuring high quality standards, with a compact design that is easy to implement and operate, significantly reducing production costs and improving product consistency.
Implementation Method 1
un known quantity of pockets (11) mounted on said input drum (9), each pocket (11) being designed to hold a corresponding wrapping sheet (3) through suction
Implementation Method 2
two folding elements (19, 20) which move with the spindle (18) along the wrapping path P2, are arranged on opposite sides of the spindle (18) and are movable independently of one another relative to the spindle (18) so as to move between a waiting position, in which the folding elements (19, 20) are farther from the spindle (18) (and therefore do not touch the wrapping sheet (3))), and a folding position, in which the folding elements (19, 20) are substantially in contact with the spindle (18) (and therefore fold the wrapping sheet (3) around the spindle (18)))
Data Source
AI summary
A manufacturing machine and a manufacturing method for the production of a filter for a tubular element. There are provided: a folding conveyor, which moves at least one first pocket along a folding path, said first pocket being designed to house a sheet made of card stock and having an inner portion and an outer portion; a feeding station, where the first pocket receives the card stock sheet and engages the sole outer portion of the card stock sheet, leaving the inner portion of the card stock sheet free; a first folding station, where the inner portion of the card stock sheet left free by the first pocket is folded like the bellows of an accordion; and an insertion station, where the first pocket releases the card stock sheet having the inner portion folded like the bellows of an accordion.