Linear Drive Container Filling Machine with Individual Runner Control
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Solution Overview
Problem
Existing container filling devices with transport star arrangements are limited by the slowest station's cycle time, leading to downtimes and inefficiencies, particularly when handling containers with liquids, as they cannot accommodate varying processing times and sloshing behaviors effectively.
Innovation Solution
A device with a linear drive arrangement featuring a closed circular path and multiple runners, each with sliding or rolling elements, allows for individual control and movement between stations, enabling continuous and intermittent operation, improved sloshing management, and the provision of a buffer for efficient container handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a transport star arrangement is used with multiple stations performing different processes, then various container processing operations can be performed simultaneously, but the slowest station determines the cycle time causing downtimes at other stations
Solution Approach 1:
The transport system is divided into independent runners that can be controlled individually. Each runner carries one or more containers and can be accelerated or decelerated independently at different stations, allowing parallel processing without synchronization bottlenecks. This segmentation eliminates the single-cycle-time constraint of traditional transport stars.
Solution Approach 2:
The system uses dynamic speed control where each runner's velocity can be adjusted in real-time based on the processing requirements at different stations. The control unit varies the speed of individual runners to match the processing time needed at each station, preventing idle time and optimizing throughput.
2Ease of operation
If containers filled with liquids are moved at constant speed, then the transport process is simple, but sloshing behavior occurs affecting filling quality
Solution Approach 1:
The system dynamically adjusts the speed of runners based on the contents being transported. For liquid-filled containers, the control unit reduces acceleration and deceleration rates to minimize sloshing. For empty containers, normal speed variations are maintained. This dynamic adaptation maintains both operational simplicity and filling precision.
Solution Approach 2:
The control unit changes the motion parameters (speed, acceleration, deceleration) of runners based on the type of containers being transported. By detecting whether containers are empty or filled with liquid, the system adjusts the speed profile accordingly, preventing sloshing while maintaining efficient transport.
3Productivity
If a linear drive arrangement with individual runner control is implemented, then continuous and intermittent movements are possible improving efficiency, but the device complexity increases
Solution Approach 1:
A single control unit performs multiple functions: it controls the speed of all runners, detects the type of containers being transported, adjusts acceleration and deceleration profiles, and coordinates the linear drive mechanism. This multi-functionality reduces the need for separate control systems for each function, managing complexity while enabling advanced features.
Solution Approach 2:
The control unit uses parameter-based control where it adjusts speed, acceleration, and deceleration parameters based on container type and station requirements. This parameter-driven approach simplifies the control logic compared to hard-wired control systems, as the same control unit can adapt to different scenarios by changing parameters rather than requiring different control circuits.
4Productivity
If the running area is arranged parallel to the drive area, then the layout is simple, but buffer capacity is limited reducing output
Solution Approach 1:
The running area is arranged at an angle (preferably 25°) to the drive area, utilizing angular space rather than linear extension. This angular arrangement creates effective buffer capacity by allowing runners to queue at an angle, increasing the number of containers that can be held in the system without significantly increasing the linear footprint of the device.
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 solution enables a compact, efficient filling process with reduced downtime, improved handling of liquid-filled containers, and increased output by allowing individual control of runners and accommodating various station processes, thereby optimizing the filling cycle and reducing sloshing issues.
Implementation Method 1
The runners include sliding elements or rolling bodies which slide or roll on the running track. As a result, low-friction movement of the runners on the running track is achieved.
Data Source
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AI summary
The present invention relates to an apparatus for filling containers (2), comprising a linear-drive arrangement (3) with a closed running path (4) and a multiplicity of rotors (6), also comprising a multiplicity of stations (7), which are arranged on the running path (4), wherein the multiplicity of stations comprise at least one filling station (7.1) for filling the containers (2), and additionally comprising a control unit (8), which is intended to drive, and stop, the rotors (6) individually.