Gas Conveyor and Brush System for Preform Alignment
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Solution Overview
Problem
In the manufacturing of thermoplastic containers, preforms often exit a straightening and alignment device in a manner that creates gaps, disrupting the continuous supply to subsequent treatment stations and reducing yield due to non-indexed positioning and occasional lack of contact between preforms.
Innovation Solution
A device comprising a centrifuge bowl with a rotating turntable and outer railing, combined with a gas conveyor system that accelerates preforms using jets of gas to ensure alignment and straightening, and a brush conveyor for final alignment and accumulation, allowing for adjustable spacing and curvature to accommodate varying preform sizes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If preforms are not indexed in position during conveyance, then the device complexity is reduced and ease of operation is improved, but gaps may occur between preforms disrupting continuous supply to downstream stations
Solution Approach 1:
The patent employs a pneumatic conveyor that uses jets of gas to accelerate preforms and maintain them in a tight line. The gas conveyor includes vent ramps that project jets of gas towards sliding preforms to push them towards the brush conveyor, ensuring continuous contact and eliminating gaps without requiring complex indexing mechanisms
Solution Approach 2:
The patent introduces a brush conveyor as an intermediary element between the centrifuge bowl and downstream stations. The brushes receive preforms from the centrifuge bowl and maintain their contact through friction, acting as a mediator that ensures continuous supply without requiring direct indexing of preforms
2Productivity
If preforms are accelerated through the system, then productivity is improved, but maintaining continuous contact between preforms becomes more difficult
Solution Approach 1:
The pneumatic conveyor uses controlled jets of gas to accelerate preforms while maintaining their contact. The vent ramps project gas jets towards the preforms to push them along the straight rails, enabling high-speed conveyance without losing continuous contact
Solution Approach 2:
The system dynamically adjusts the conveyance method through different zones: the centrifuge bowl provides initial acceleration and alignment, the gas conveyor maintains acceleration and contact, and the brush conveyor provides final alignment and accumulation. This dynamic approach allows high productivity while maintaining continuous contact
3Adaptability or versatility
If the system is designed to accommodate varying preform sizes, then adaptability is improved, but device complexity increases due to adjustable components
Solution Approach 1:
The system incorporates adjustable straight rails and branch rails that can be repositioned to accommodate different preform sizes. The gauge of the straight rails can be adjusted, and the branch rails can be replaced to adapt their radius of curvature and gauge, providing versatility without overly complex mechanisms
Solution Approach 2:
The centrifuge bowl design with adjustable parameters serves multiple functions: it aligns preforms, straightens them, and accommodates different sizes. The same basic structure can handle various preform formats by adjusting the bowl parameters, reducing the need for completely different mechanisms for each size
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
Ensures continuous and efficient supply of preforms to downstream processing stations by maintaining a consistent line without gaps, enhancing manufacturing yield and adaptability to different preform formats.
Implementation Method 1
a gas conveyor system that accelerates preforms using jets of gas to ensure alignment and straightening
Implementation Method 2
a device comprising a centrifuge bowl with a rotating turntable and outer railing
Implementation Method 3
a brush conveyor for final alignment and accumulation
Data Source
Figure 1~3
Figure 4~13
Figure 14
AI summary
Arrangement for pressing together queuing preforms (12) at the output of a device (10) for straightening and aligning preforms, in particular thermoplastic material preforms (12) intended to be formed into an end container by a forming station. The arrangement comprises an output conveyor consisting of a brush conveyor (22) and a gas-type conveyor (56), arranged directly upstream of the brush conveyor (22), for blowing jets (68) of pressurized gas onto the preforms (12) entering the gas-type conveyor and accelerating their sliding movement towards the brush conveyor (22).