Form Fill Machine Ullage Control via Stretching Rod Depth Adjustment
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Solution Overview
Problem
The existing methods for molding and filling plastic containers using stretching rods or filler necks often result in variable and potentially lower-than-desired final filling levels due to the displacement of volume by these inserts, leading to inconsistent ullage and potential overspill.
Innovation Solution
The method involves adjusting the insertion depth of the stretching rod or filler neck at the end of the filling process to match a predetermined desired ullage, ensuring precise control over the final filling level by using an adjustment unit that can be controlled manually or via a closed-loop system, allowing for continuous or discrete adjustments based on predetermined values and real-time measurements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a stretching rod or filler neck is inserted into the plastic container during filling, then the container can be molded and filled in a single process, but the insertion of the stretching rod or filler neck displaces volume in the product, causing the final filling level to drop and vary
Solution Approach 1:
The patent applies preliminary action by pre-calculating and pre-setting the insertion depth of the stretching rod or filler neck based on the desired final filling level. The system determines the required insertion depth before filling begins, accounting for the volume displacement that will occur when the rod is removed. This allows the filling process to compensate in advance for the volume displacement, ensuring the desired final filling level is achieved.
Solution Approach 2:
The patent applies parameter changes by dynamically adjusting the insertion depth parameter of the stretching rod or filler neck during the filling process. The system modifies the insertion depth based on real-time feedback from filling level sensors, allowing precise control over the volume displacement and consequently the final filling level. This dynamic parameter adjustment enables the system to maintain high filling precision while using the stretching rod method.
2Manufacturing precision
If the stretching rod or filler neck is inserted deeper to account for volume displacement, then the final filling level may be maintained, but the ullage becomes larger than desired
Solution Approach 1:
The patent applies feedback by implementing a closed-loop control system that continuously monitors the filling level using sensors and adjusts the insertion depth of the stretching rod or filler neck in real-time. The system compares the actual filling level with the desired filling level and dynamically modifies the insertion depth to compensate for volume displacement. This feedback mechanism ensures both precise filling level control and optimal ullage management, as the system learns and adapts to the specific volume displacement characteristics of each filling operation.
3Manufacturing precision
If the insertion depth is adjusted dynamically during the filling process, then the final filling level can be precisely controlled, but the device complexity increases
Solution Approach 1:
The patent applies mechanics substitution by replacing complex mechanical adjustment mechanisms with a control system that uses sensors and automated actuation. Instead of requiring manual intervention or complex mechanical linkages to adjust the insertion depth, the system uses electronic sensors to detect the filling level and an automated actuator (such as a motorized positioning system) to adjust the stretching rod or filler neck depth. This substitution of mechanical systems with automated control reduces overall device complexity while maintaining high precision filling level control.
Data Source
AI summary
A method and apparatus for forming, by means of expansion, plastic preforms into plastic containers in a hollow mold and for filling a substantially liquid product or at least a liquid or solid component of the product into the plastic containers in the hollow mold. The product is filled into the plastic containers while the respective plastic container has inserted therein, at least partially, a stretching rod or a filler neck, and the insertion depth of the stretching rod or of the filler neck is, at the end of the filling process, adjusted such that the volume displaced in the product by the stretching rod or the filler neck corresponds to a predetermined desired ullage.