Packaging Machine Dual-Sensor Splice Detection for Sterile Tube Sealing
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Solution Overview
Problem
Existing packaging machines face challenges in efficiently and economically detecting splices in packaging material during the production of sealed packages, particularly in maintaining a sterile environment while ensuring precise detection and adjustment of the tube forming and sealing process.
Innovation Solution
A packaging machine with a control apparatus featuring dual sensing elements, one contact and one contactless optic sensing element, is used to detect splices in packaging material before and after sterilization, allowing for precise positioning and adjustment of the tube forming and sealing process, thereby improving detection accuracy and reducing material damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single sensing element is used to detect splices, then the device complexity is reduced, but the measurement precision and reliability of splice detection deteriorates
Solution Approach 1:
The detection system is segmented into two distinct sensing elements: a first sensing element positioned before the sterilizing unit and a second sensing element positioned after the sterilizing unit. Each sensing element independently detects splices in the web of packaging material, allowing the system to maintain simplicity while improving detection precision through multiple measurement points.
2Measurement precision
If dual sensing elements are used to detect splices before and after sterilization, then the measurement precision is improved, but the device complexity increases
Solution Approach 1:
The first sensing element performs preliminary detection of splices in the web of packaging material before the web enters the sterilizing unit. This preliminary action allows the control apparatus to be alerted to potential splice issues before sterilization occurs, enabling proactive adjustment of the tube forming and sealing process parameters to prevent defects.
Solution Approach 2:
The control apparatus receives signals from both the first sensing element (before sterilization) and the second sensing element (after sterilization). This feedback mechanism allows the system to compare detections from both positions and automatically adjust the tube forming and sealing process accordingly, improving measurement precision while managing device complexity through intelligent control.
3Manufacturing precision
If the tube forming and sealing process is adjusted based on splice detection, then the manufacturing precision is improved, but the productivity decreases due to process adjustments
Solution Approach 1:
By detecting splices before sterilization with the first sensing element, the system can proactively adjust tube forming and sealing parameters in advance. This preliminary adjustment prevents manufacturing defects without requiring post-sterilization corrections, thereby maintaining both high manufacturing precision and productivity.
Solution Approach 2:
The control apparatus automatically changes process parameters of the tube forming and sealing device based on splice detection signals. These parameter changes are optimized to maintain package sealing precision while minimizing interruptions to the packaging production speed, thus balancing manufacturing precision and productivity.
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
The dual sensing system enhances the precision and reliability of splice detection, ensuring seamless operation of the tube forming and sealing process, reducing material defects, and maintaining sterility throughout the packaging process.
Implementation Method 1
a contactless optic sensing element arranged along the conveying path P and configured to detect the splice S of packaging material by receiving a light beam reflected from the web 4 of packaging material
Data Source
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AI summary
It is described a packaging machine (1) for producing sealed packages from a web (4) of packaging material fed along a conveying path (P) with a tube forming and sealing unit (9) arranged along said conveying path (P) for folding said web (4) of packaging material from a planar shape into a tube (10) and for longitudinally sealing said tube (10); an isolation chamber (C) delimiting an inner sterile/aseptic environment (IE) from an outer environment (OE), wherein the tube forming and sealing unit (9) is at least partially arranged within the isolation chamber (C); and a control apparatus (19) having a first sensor device (20) arranged along said conveying path (P) upstream of the isolation chamber (C) and configured to detect a splice (S) of packaging material and a second sensor device (23) arranged along said conveying path (P) in the area of the isolation chamber (C) and configured to detect the splice (S) of packaging materials.