Looped Chain Transport for Beverage Capsule Production
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing beverage capsule machines have low productivity per unit time and are cumbersome and expensive due to the need for multiple operating stations in a step-by-step production process, which compromises operational reliability and machine size.
Innovation Solution
A beverage capsule machine with a continuously moving looped chain transport element that carries a single row of pockets for rigid containers, featuring stations for feeding, dosing, closing, and outfeeding, allowing for high-speed production in a compact space with reduced operating stations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a step-by-step production process with multiple operating stations is used, then manufacturing precision and process control are improved, but productivity per unit time deteriorates
Solution Approach 1:
The production process is segmented into multiple operating stations (feeding station, dosing station, closing station, outfeed station) that operate independently along the conveyor belt. Each station performs a specific function and can operate continuously as capsules pass through, transforming the sequential step-by-step process into a parallel continuous process that maintains precision while improving productivity.
Solution Approach 2:
The conveyor belt creates continuous motion that allows all operating stations to function simultaneously rather than sequentially. Capsules move continuously through feeding, dosing, closing, and outfeed stations without interruption, enabling the system to maintain high productivity while preserving manufacturing precision through coordinated continuous operation.
2Productivity
If the conveyor belt is made wider to form multiple rows of pockets, then productivity per unit time is improved, but device complexity and machine size increase
Solution Approach 1:
Instead of increasing the width of the conveyor belt to create multiple rows of pockets, the invention uses the time dimension by making the belt continuous and looping. Multiple capsules are processed at different times along the same single-row path, achieving high productivity without the complexity of multiple parallel stations or widened belt structure.
Solution Approach 2:
The single-row conveyor belt serves multiple functions by cycling through different operational phases. The same belt and pocket structure that feeds capsules at one station later receives them at the dosing station, then at closing, and finally at outfeed, eliminating the need for separate dedicated paths for each operation and reducing overall device complexity.
3Productivity
If multiple operating stations are placed side by side in a horizontal plane, then productivity is improved, but the machine becomes more cumbersome and expensive
Solution Approach 1:
The system transforms static side-by-side station placement into dynamic sequential processing along a moving conveyor belt. Stations are arranged linearly along the belt's path rather than in a horizontal plane, and the continuous motion of the belt creates dynamic overlap where multiple stations operate simultaneously on different capsules, reducing the machine's horizontal footprint while maintaining productivity.
Solution Approach 2:
Capsules are prepared and positioned at feeding stations before reaching dosing stations, and dosing occurs before capsules arrive at closing stations. This preliminary sequencing of actions along the conveyor path allows stations to be spaced efficiently rather than placed adjacent to each other, reducing the overall machine length while maintaining continuous high-speed production.
4Device complexity
If a single production line with step-by-step operation is used, then device complexity is reduced, but productivity per unit time deteriorates
Solution Approach 1:
The continuous conveyor belt system maintains relatively simple device complexity while dramatically improving productivity. Instead of capsules stopping at each station for sequential processing, the continuous belt movement allows all stations to operate simultaneously on different capsules in the pipeline, transforming a simple single-line design into a high-productivity continuous processing system without adding significant complexity.
Data Source
AI summary
A beverage capsule machine for making single use capsules (1) for infusion beverages such as coffee, milk, chocolate, tea or combinations of these ingredients, comprises: a transport element (8) for transporting rigid containers (2) and being dosed in a loop around movement means (9), with a vertical axis (Z9), for continuously moving the transport element (8); the element (8) being configured to define a plurality of pockets (10) for receiving the rigid containers (2) and arranged in succession, each having a respective vertical axis (Z10); a plurality of stations which are positioned along a path (P) followed by the transport element (8) and which are configured for operating continuously in phase with the transport element (8) and comprising at least: a feeding station (11) for feeding the rigid containers (2) into the respective pockets (10) of the transport element (8); a dosing station (12) for dosing the infusion product into the rigid container (2); a closing station (13) where the open aperture (4) of the rigid container (2) is closed with a length of sheet (7); an outfeed station (14) for feeding out the capsules (1) made on the transport element (8).