Packaging Machine Foreign Substance Detection
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Solution Overview
Problem
Existing packaging machines often suffer tool damage during the sealing process due to misaligned packaging items or trays, leading to extended downtime for maintenance and tool replacement.
Innovation Solution
The packaging machine incorporates detection means such as cameras, pressure sensors, and ultrasonic sensors to identify misaligned items or trays, preventing the tools from pressing together and causing damage, with control units to stop the movement of tools upon detection, and includes heating and cooling elements for efficient sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the upper tool and lower tool are pressed together during sealing operation, then the cover film is sealed to the tray, but the tools may be damaged by misaligned packaging items or trays
Solution Approach 1:
The detection means (camera, pressure sensor, or ultrasonic sensor) inspect the tray and packaging items before the sealing operation begins. Misalignment is detected in advance, and the control unit prevents the tools from pressing together, avoiding tool damage before it occurs
Solution Approach 2:
The detection means continuously monitor the position of trays and packaging items during the sealing process. When misalignment is detected, the control unit receives feedback and immediately stops or reverses the tool movement, preventing contact between misaligned items and the tools
2Reliability
If detection means are added to detect misaligned items, then tool damage is prevented, but device complexity increases
Solution Approach 1:
The patent introduces detection means as an intermediary system between the packaging process and the sealing tools. This intermediary layer detects misalignment and communicates with the control unit, which then adjusts tool movement accordingly, preventing direct damage without requiring complex modifications to the sealing tools themselves
Solution Approach 2:
The patent replaces purely mechanical alignment verification with sensor-based detection systems (camera, pressure sensor, or ultrasonic sensor). These electronic/optical detection means substitute for mechanical inspection methods, providing more reliable and automated misalignment detection while reducing the need for complex mechanical adjustments
3Reliability
If the movement of tools is stopped upon detection of misalignment, then tool damage is avoided, but productivity decreases
Solution Approach 1:
When misalignment is detected, the control unit quickly stops or reverses tool movement, minimizing the time the tools are in a dangerous position. The system then rapidly resets and continues operation, skipping only the brief moment when misalignment would cause damage while maintaining overall production flow
Solution Approach 2:
The detection means operate continuously before and during the sealing process, identifying misalignment issues before they can cause damage. By detecting problems in advance and preventing tool contact only when necessary, the system maintains high productivity for properly aligned items while protecting tools from damage
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
Prevents tool damage by ensuring proper alignment, reducing downtime and extending the operational life of the machine, while allowing for efficient sealing of trays with various types of cover films and trays.
Implementation Method 1
the means to detect a misaligned packaging item in the tray, a misaligned tray during the sealing of the cover film to the tray
Implementation Method 2
the means to detect a misaligned packaging item in the tray, a misaligned tray during the sealing of the cover film to the tray
Implementation Method 3
the means to detect a misaligned packaging item in the tray, a misaligned tray during the sealing of the cover film to the tray
Implementation Method 4
At least one of these tools is heated so that heat can be applied to one of the film and/or to the tray during the sealing operation
Implementation Method 5
At least one of these tools is heated so that heat can be applied to one of the film and/or to the tray during the sealing operation
Implementation Method 6
At least one of the tools can comprise cooling means to cool the respective tool in certain regions, to avoid undesired shrinkage of the cover film and/or the tray
Data Source
Figure 1
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Figure 3
AI summary
The present invention relates to a packaging machine (1) which seals a cover-film (6) at a tray (4), which has been previously filled with a packaging item (5), whereas the packaging machine comprises an upper tool (2) and a lower tool (3) which are pressed together during the sealing of the cover-film (6) to the tray (4), and which comprises means (7) to detect misalignment of the packaging item in the tray (4), a misaligned tray in the lower tool (3) and/or a foreign object between the upper and the lower tool (3) prior to and/or during the sealing of the cover film (6) to the tray (4).