Continuous Motion Linear Filler Nozzle Synchronization
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Solution Overview
Problem
Existing linear container filling machines are slower than rotary machines due to stopping at filling stations and slow conveyor speeds needed for alignment, which offsets space-saving advantages.
Innovation Solution
A continuous motion linear filling machine with nozzles in constant motion, synchronized by a microcontroller to move in a coordinated manner with a conveyor, allowing simultaneous filling of multiple rows of containers without dwell periods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If linear filling machines stop bottles at the filling station to align with nozzles, then filling precision is improved, but filling speed deteriorates
Solution Approach 1:
The patent applies dynamics by making the nozzle assembly movable rather than stationary. The carriage assembly with nozzles reciprocates horizontally and moves vertically to synchronize with container motion, eliminating the need to stop containers for alignment. This dynamic positioning maintains precise alignment while keeping containers in continuous motion, resolving the contradiction between alignment precision and filling speed.
Solution Approach 2:
The patent implements periodic action through the reciprocating motion of the horizontal carriage that moves nozzles back and forth in synchronization with container flow. The vertical carriage periodically lowers nozzles to engage containers and raises them to disengage. This periodic motion pattern ensures continuous filling without stopping containers, maintaining both precision and speed.
2Manufacturing precision
If conveyors move bottles slowly for alignment, then alignment accuracy is improved, but filling rate deteriorates
Solution Approach 1:
The system makes both the conveyor and nozzle assembly dynamic. The conveyor moves containers at optimized speeds while the nozzle assembly dynamically adjusts its position through horizontal and vertical carriage motion to maintain precise alignment. This eliminates the constraint of slow conveyor speed, allowing faster filling rates without sacrificing alignment accuracy.
Solution Approach 2:
The patent adds dimensional freedom by introducing vertical motion of the nozzle assembly in addition to horizontal reciprocating motion. This two-dimensional movement capability allows nozzles to precisely track and engage containers along their path, maintaining alignment accuracy while enabling higher conveyor speeds and thus higher filling rates.
3Device complexity
If nozzles remain stationary at filling position, then device complexity is reduced, but filling speed deteriorates due to dwell periods
Solution Approach 1:
The patent transforms the stationary nozzle system into a dynamic one with horizontal and vertical motion capabilities. The horizontal carriage reciprocates to position nozzles, and the vertical carriage lowers and raises them for engagement. This dynamic system eliminates dwell periods where nozzles would otherwise remain idle, significantly increasing filling speed despite the added mechanical complexity.
Solution Approach 2:
The patent ensures continuity of useful action by keeping nozzles in constant motion synchronized with container flow. The horizontal carriage continuously reciprocates and the vertical carriage continuously adjusts engagement, eliminating idle dwell periods. This continuous operation maximizes filling speed by ensuring nozzles are always positioned optimally rather than remaining stationary with periodic idle times.
Data Source
AI summary
A conveyor and carriage assembly are synchronized to increase the speed of operation and eliminate any dwell periods to improve the rate at which a linear container filler is able to fill containers with a material. The fill rate approaches or exceeds that of prior art linear and rotary filling machines.