Automatic Packing Machine Format Change With Component Verification
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Solution Overview
Problem
Automatic packing machines for cigarettes face challenges in frequent format changes, requiring expert intervention and complex maintenance scheduling due to components linked to specific formats, leading to potential errors and mechanical breakdowns.
Innovation Solution
The implementation of an assistance method using electronic identification devices with programmable memories and wireless communication, allowing for automatic detection and replacement of components during format changes, and enabling efficient maintenance scheduling through data storage and communication with the control unit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If expert technical personnel intervene to replace components during format changes, then the reliability of component replacement is improved, but the complexity of the operation and time consumption increase
Solution Approach 1:
The system enables non-expert operators to perform format changes independently through automated guidance. The control unit provides step-by-step instructions, automatically detects component presence/absence, and manages the replacement process without requiring expert intervention, thus making the system self-servicing for format changes.
Solution Approach 2:
The system continuously monitors the format change process through automatic detection of component presence and absence. The control unit receives feedback from sensors and electronic identification devices, processes this information, and adjusts the guidance instructions accordingly to ensure correct component replacement and maintain reliability.
2Ease of manufacture
If manual tracking of component operation hours is used, then the maintenance scheduling simplicity is improved, but the measurement precision of actual component usage deteriorates
Solution Approach 1:
Electronic identification devices equipped with programmable memories serve as intermediaries between components and the control unit. These devices automatically record and store component operation hours and format change data, which are then transmitted to the control unit for automated maintenance scheduling, eliminating manual tracking while maintaining precision.
Solution Approach 2:
The patent replaces manual mechanical tracking methods with automated electronic monitoring systems. Sensors and electronic identification devices automatically detect and record component usage data, substituting human intervention with electronic measurement and data processing systems that provide precise tracking without complex manual procedures.
3Adaptability or versatility
If frequent format changes are implemented to adapt to market demands, then the adaptability of production is improved, but the frequency of maintenance interventions and potential errors increase
Solution Approach 1:
The system performs preliminary detection and verification actions before and during format changes. The control unit automatically checks component presence, validates configuration changes, and ensures proper installation before resuming production, preventing errors that could arise from frequent format changes while maintaining production flexibility.
4Extent of automation
If electronic identification devices with wireless communication are implemented, then the automation extent of component detection is improved, but the device complexity and implementation cost increase
Solution Approach 1:
Electronic identification devices perform multiple functions: they store component information in programmable memories, provide wireless identification signals, record operation hours, and communicate with the control unit. This multi-functionality reduces the need for separate systems while achieving high automation in component detection and management.
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
This method enables safe and efficient format changes even by non-expert operators, simplifies the implementation process, and ensures precise maintenance programming, reducing the risk of errors and mechanical issues.
Implementation Method 1
each component comprising an electronic identification device (16) having a programmable memory (17) and a wireless communication member (18)
Data Source
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AI summary
An assistance method for the execution of a format change in an automatic machine (6) for manufacturing or packing smoking, hygiene, food or pharmaceutical products. The assistance method comprises the steps of: dividing the format change into an orderly succession of operations for the removal of components designed for the old format and installation of components designed for the new format; communicating the orderly succession of removal and installation operations to an operator in charge of the format change; electronically and automatically detecting the actual presence or absence of a component designed for the old or new format before communicating to the operator the operation for the removal or installation of the component; electronically and automatically detecting the actual absence or presence of a component designed for the old or new format after having communicated to the operator the operation for the removal or installation of the component; and communicating to the operator the operation following an operation for the removal or installation of a component only after having electronically and automatically checked for the actual absence or presence of the component.