Flexible Diving Funnel for Pouch Filling

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Solution Overview

Problem

Automated manufacturing processes face inefficiencies in loading preformed pouches into high-speed fill-seal machines due to the need for manual adjustment of pouch specifications and gripper width, leading to downtime and increased labor costs, as well as issues with pouch opening and filling due to rigid diving funnels causing damage and jams.

Innovation Solution

A system utilizing a robotic transfer device with an optical sensor to determine pouch dimensions and adjust gripper width automatically, combined with a reciprocating opening mechanism and flexible diving funnel to ensure precise and continuous loading and filling of pouches without manual intervention.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If a robotic transfer device is used to load pouches at high speed, then productivity is improved, but the device requires precise teaching of pouch specifications which causes downtime and increases labor costs

Engineering Contradiction:

Improveloading speedVSAvoiddowntime for teaching

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The system uses an optical sensor to automatically read indicia on the pouch and a controller to automatically determine pouch characteristics and adjust robotic transfer device parameters, eliminating the need for manual teaching and entry of specifications

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent replaces manual mechanical adjustment and teaching procedures with an automated optical sensing and control system that reads pouch indicia and automatically configures the robotic transfer device parameters

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Adaptability or versatility

If the fill-seal machine is shut down for manual adjustment of gripper width, then adaptability to different pouch sizes is improved, but productivity decreases due to downtime

Engineering Contradiction:

Improvegripper adjustmentVSAvoidmachine downtime

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The system automatically determines pouch characteristics from scanned indicia and self-adjusts the gripper width without requiring operator intervention or machine shutdown

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The optical sensor provides feedback about pouch dimensions through the scanned indicia, allowing the controller to automatically adjust gripper width to match the specific pouch being loaded

Inventive Principle:

Principle #23Feedback

3Productivity

If a rigid diving funnel is used to fill the pouch, then filling speed is improved, but the contents are damaged and jams occur

Engineering Contradiction:

Improvefilling speedVSAvoiddamage to contents

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The patent replaces the rigid diving funnel with a flexible funnel that can adapt to the pouch contents and opening, preventing damage while maintaining filling capability

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The funnel transitions from a rigid structure to a flexible one, changing the physical parameter of structural rigidity to eliminate damage and jams while preserving filling function

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS9771174B2Flexible funnel for filling a pouch with a product

Publication Date: 2017.09.26 POUCH PAC INNOVATIONS LLC

AI summary

A flexible funnel positioned at a filling station of a fill machine. The flexible funnel directs a product dispensed at the filling station of the filling machine into a pouch. The flexible funnel having a rigid upper portion and a plurality of fingers. The rigid upper portion includes an open top end and an open bottom end. Each of the plurality of elongated fingers hingedly connected to the upper portion. The rigid upper portion has a regular polygon shape having a plurality of sides, and each of the plurality of fingers is individually articulatable with respect to one of the plurality of sides of the upper rigid portion.