Flexible Packaging Machine with Dynamic Transport Routes
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Solution Overview
Problem
Conventional packaging machines for the tobacco industry are inflexible and require extensive reworking or new machines for product changes, leading to high costs and downtime, especially when producing different products or pack configurations.
Innovation Solution
A machine with multiple workstations that can perform different sequences of assembly operations, allowing for flexible production of various tobacco products and packaging materials, enabling quick changes between product types and pack configurations without the need for new machines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional packaging machines are used for dedicated high-speed production, then productivity is improved, but adaptability deteriorates requiring extensive reworking for product changes
Solution Approach 1:
The patent implements dynamic reconfigurability by allowing the transport route and workstation sequence to be selectively changed based on production requirements. The machine can switch between different transport routes (first route for first pack configuration, second route for second pack configuration) and activate different subsets of workstations, enabling rapid adaptation to different products and pack configurations without physical reconfiguration or downtime.
Solution Approach 2:
The packaging machine is designed with universal functionality to handle multiple pack configurations using the same physical hardware. By providing multiple transport routes and enabling selective activation of workstations, a single machine can perform the function of multiple dedicated machines, producing different pack configurations (first pack configuration and second pack configuration) without requiring extensive reworking or new equipment.
2Manufacturing precision
If dedicated single-purpose machines are used, then manufacturing precision is improved, but device complexity increases for reconfiguration
Solution Approach 1:
The system maintains manufacturing precision through dynamic selection of appropriate workstations and transport routes for each pack configuration. The controller selectively activates only the necessary workstations and transport route needed for the current production run, ensuring that packaging accuracy is maintained while avoiding the complexity of physically reconfiguring the entire machine for different products.
3Productivity
If high-speed packaging machines operate continuously, then productivity is improved, but loss of time increases during shutdowns for maintenance or product changes
Solution Approach 1:
The patent minimizes downtime by enabling dynamic switching between different transport routes and workstation configurations. When a product change or maintenance is needed, the controller can selectively deactivate certain workstations and switch to an alternative transport route and workstation sequence, allowing the machine to continue operating with reduced interruption rather than requiring complete shutdown and extensive reconfiguration.
Solution Approach 2:
The system maintains continuous production by providing alternative transport routes and workstation sequences. When one route or set of workstations requires maintenance or reconfiguration, the controller can switch to another route, ensuring that the packaging operation continues without interruption. This redundancy enables seamless transitions between different pack configurations while maintaining continuous useful action.
Data Source
AI summary
A method and machine for packaging smoking articles or other tobacco industry products in which the products and packaging may be transported from selected product supply systems and packaging material supply systems selectively along a plurality of alternative transport routes through the machine through a series of workstations arranged to incorporate batches of smoking products selectively in different packaging materials according to the transport route selected.