Inline Packaging Machine Adjustable Carrier Tracks
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Solution Overview
Problem
Conventional packaging machines are inefficient due to lengthy changeover times when switching between different sized pouches, requiring significant operator intervention and resulting in reduced throughput and operating efficiency.
Innovation Solution
An inline packaging machine with adjustable carrier tracks and a control system that allows for rapid changeovers between different sized pouches, enabling automatic adjustment and processing of varying pouch sizes, reducing changeover time to less than 30 seconds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional carousel packaging machines are used to fill pouches, then the machine can process pouches effectively, but the machine has a large footprint and is not adjustable to accommodate different sized containers
Solution Approach 1:
The packaging machine is divided into separate functional modules (loading station, opening station, filling station, sealing station) arranged in a compact linear configuration rather than a large carousel structure. Each module handles a specific task, allowing the machine to accommodate different pouch sizes without requiring a large footprint while maintaining full functionality.
2Adaptability or versatility
If operators manually adjust the carousel to handle different sized containers, then the machine can process various pouch sizes, but the changeover time increases to 30-40 minutes
Solution Approach 1:
The carrier tracks are designed with adjustable positions that can be quickly reconfigured using actuators and positioning mechanisms. The system includes multiple predetermined positions along the inline path that allow rapid adjustment of track spacing and configuration to accommodate different pouch sizes, reducing changeover time from minutes to seconds.
Solution Approach 2:
The machine allows rapid changeover by adjusting key parameters such as carrier track spacing, clamp positions, and station alignments. These parameters can be quickly modified through automated positioning systems and programmable control, enabling the machine to adapt to different pouch dimensions without lengthy manual reconfiguration.
3Adaptability or versatility
If operators spend valuable time adjusting the carousel for different sized containers, then the machine can be reconfigured, but the machine is off-line and inoperative during adjustment
Solution Approach 1:
The system is pre-programmed with multiple preset configurations for different pouch sizes. Before a changeover is needed, the appropriate configuration parameters are loaded into the control system. When changeover is required, the system automatically executes the pre-programmed adjustments, eliminating the need for operators to manually reconfigure components during production transitions.
Solution Approach 2:
The packaging machine performs its own reconfiguration automatically through programmable logic controllers and automated positioning systems. The control system manages the entire changeover process, adjusting carrier tracks, clamps, and station positions without requiring operator intervention, thereby maintaining continuous operation and high productivity.
4Area of stationary object
If a compact inline machine design is used, then the footprint is reduced, but the machine must accommodate varying pouch sizes through adjustable components
Solution Approach 1:
The adjustable carrier tracks and clamps serve multiple functions: they securely hold pouches during processing, allow rapid repositioning for different sizes, and can be programmed to accommodate various pouch configurations. This multi-functionality reduces the need for multiple specialized components, simplifying the overall system while maintaining compact dimensions and adaptability.
Data Source
AI summary
An inline packaging machine for automatically accommodating and filling different sized containers, such as pouches, to reduce changeover time and thereby improve operating efficiency of the machine. The machine includes stations disposed longitudinally along a center line of the machine, including a first carrier track opposing a second carrier track with respect to the center line. A first clamp is disposed on the first carrier track and at least a second clamp is disposed on the second carrier track wherein the clamps are configured to releasably secure first-sized pouches for filling. The pouches are advanced inline from a setup station through an opening station to a filling station for filling with contents. The filled pouches are then advanced to a sealing and discharging station. A control system automatically adjusts the distance between the corresponding clamps to accommodate second-sized and/or third-sized pouches for inline processing and filling.