Flip-Off Cap Removal Mechanism for Automated Bottle Handling

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing flip-off caps for pharmaceutical bottles are manually opened, hindering automation in pharmaceutical handling lines and requiring manual intervention, which increases the risk of microbiological contamination.

Innovation Solution

An apparatus comprising a removal station with a gripping head, belt conveyor, and electronic control unit to automate the removal of flip-off caps from bottles, ensuring gentle handling and integration into industrial processing lines.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Extent of automation

If manual opening of flip-off caps is used, then the cap can be easily removed by pulling movement, but automation cannot be achieved and microbiological contamination risk increases

Engineering Contradiction:

Improveautomation of cap removalVSAvoidmicrobiological contamination risk

Core Design Contradiction:

Extent of automationVSObject-affected harmful factors

Solution Approach 1:

The patent replaces the manual mechanical pulling action with an automated gripping mechanism that uses controlled mechanical forces. The gripping head applies localized force to the cap's protrusion, replicating and automating the manual removal action while eliminating human contact and contamination risk.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The apparatus enables self-service automation where the system automatically performs the cap removal operation without requiring manual intervention. The gripping mechanism is designed to automatically grasp, lift, and remove the cap through programmed movements, making the process autonomous and sterile.

Inventive Principle:

Principle #25Self-service

2Extent of automation

If automated cap removal apparatus is designed, then automation can be achieved, but the apparatus complexity increases

Engineering Contradiction:

Improveautomation of cap removalVSAvoidapparatus structure complexity

Core Design Contradiction:

Extent of automationVSDevice complexity

Solution Approach 1:

The apparatus is divided into functional modules: a gripping head with jaws, a positioning mechanism, and a removal actuation system. Each module performs a specific function (grasping, positioning, removing) and can be independently designed and maintained, reducing overall system complexity while enabling automation.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The gripping head acts as an intermediary mechanism between the automated system and the cap. It translates automated commands into physical gripping actions through a simplified mechanical interface, avoiding the need for complex direct actuation mechanisms while maintaining automation capability.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Productivity

If force is applied to remove the cap, then the cap can be detached from the ferrule, but the ferrule cap or bottle may be damaged

Engineering Contradiction:

Improvecap removal efficiencyVSAvoidintegrity of ferrule cap and bottle

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The gripping jaws are designed to apply force locally to the cap's protrusion area, which is the only point needing detachment. The force is concentrated at this specific location while the rest of the ferrule cap and bottle remain unaffected, enabling efficient removal without damage through localized mechanical action.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The gripping mechanism is designed to gradually apply and control the detachment force, preventing sudden or excessive forces that could damage the ferrule cap or bottle. The mechanical design inherently cushions and distributes the removal force to ensure gentle detachment while maintaining productivity.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Data Source

PatentEP3932816B1Apparatus for removing a flip-off type plastic cap from a bottle

Publication Date: 2025.10.01 COMECER

Figure 1~2
Figure 3
Figure 4

AI summary

Apparatus for removing a flip-off type plastic cap from a ferrule cap of a bottle, having: a holding system (10) to hold the bottle (1) upright with its own longitudinal axis (2a) coinciding with a fixed first axis (12); a gripping head (14) provided with a gripper (15) having two jaws (16, 17) mutually movable along a second axis (18) transverse to the first axis (12) to grip the cap (4); first handling arms (31, 32) to move the gripping head (14) to and from the bottle (1), second handling arms (36, 37) to rotate the gripping head (14) about a third axis (20) placed on the side of a first jaw (16) and perpendicular to a plane defined by a first axis and by a second axis (12, 18); and an electronic control unit (27) configured to control the handling arms (31, 32, 36, 37) and the gripper (15) so as to bring the gripping head (14) closer to the bottle (1) and rotate it so as to position the two jaws (16, 17) around the cap (4) with the second axis (18) perpendicular to the first axis (12), close the gripper (15) so as to grip the cap (4), rotate the gripping head (14) around the third axis (20) by a certain angle (β) such as to lift the cap (4) from the ferrule cap (3) only at the second jaw (17), and move the gripping head (14) away from the bottle (1) while the gripping head (14) remains rotated by that angle (β) so as to remove the plastic cap (4) from the ferrule cap (3).