Packaging Machine Pressure Profile Control for Fill Level Consistency
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Solution Overview
Problem
Existing packaging machines produce packs with varying appearances due to uneven filling levels, leading to inconsistent packaging quality, especially when dealing with products of varying densities like sliced meat or cheese, and require manual adjustment of process parameters, which is inefficient and prone to errors.
Innovation Solution
A method and device that use a pressure-detecting sensor system to record and compare pressure profiles during the gassing process, allowing for real-time calculation of the degree of filling and adjustment of process parameters to maintain consistent packaging appearance, even with varying filling levels, by referencing a known empty packaging pressure profile.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a preset gassing offset pressure is used to compensate for the sealing stroke pressure increase, then the target pressure can be achieved under constant filling conditions, but the packaging appearance varies when filling levels differ
Solution Approach 1:
The patent applies feedback by measuring the actual pressure profile during gassing and using this information to adjust the gassing offset pressure dynamically. The control unit continuously monitors pressure deviations and adapts the offset pressure for subsequent packaging cycles, enabling the system to compensate for varying filling levels and maintain consistent packaging appearance.
Solution Approach 2:
The patent transforms the static, preset gassing offset pressure into a dynamic parameter that automatically adapts to changing filling conditions. The control unit adjusts the offset pressure in real-time based on measured pressure profiles, allowing the system to respond to varying product densities and filling levels without manual intervention.
2Manufacturing precision
If manual adjustment of gassing parameters is performed, then some adaptation to filling variations is possible, but the process is inefficient and prone to errors
Solution Approach 1:
The patent implements self-service by enabling the packaging machine to automatically measure, analyze, and adjust gassing parameters without operator intervention. The control unit autonomously monitors pressure profiles and adapts the gassing offset pressure, eliminating manual adjustments and their associated errors while maintaining high production efficiency.
Solution Approach 2:
The patent replaces manual mechanical adjustment with an automated electronic control system. The control unit uses electronic sensors to measure pressure and electronically adjusts the gassing parameters, substituting the manual mechanical process with an automated system that is both efficient and precise.
3Ease of operation
If the sealing tool is positioned set back during gassing to create a gap for gas distribution, then gas can flow into all packages, but the subsequent sealing stroke displaces volume and increases pressure
Solution Approach 1:
The patent uses feedback to measure the pressure increase caused by the sealing stroke and compensates for it by adjusting the gassing offset pressure. The control unit monitors the pressure profile during and after the sealing stroke and adapts the offset pressure to account for the volume displacement effect, maintaining consistent packaging appearance despite the mechanical sealing process.
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 approach enables the production of packaging with a consistent appearance by dynamically adjusting the gassing process parameters based on actual filling levels, reducing rejects and ensuring optimal packaging quality, particularly for products with varying densities.
Implementation Method 1
recording a pressure profile at least temporarily during the filling of the packaging volume by means of at least one pressure-detecting sensor system connected thereto
Implementation Method 2
Filling a free packaging volume enclosed between a lower and an upper packaging material, at least one packaging positioned within the sealing station, with a gas intended to create a desired atmosphere from an initial pressure prevailing in the packaging volume to a predetermined gassing pressure
Data Source
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AI summary
Method for operating a sealing station (3) of a packaging machine (1) for producing packaging (V) with at least substantially similar packaging appearances, possibly with varying fill levels (22), comprising performing a comparison (C) of a detected pressure profile (27) with a reference pressure profile (28), calculating (D) a fill level (22) of the packaging (V) positioned within the sealing station (3) based on the comparison of the detected pressure profile (27) with the reference pressure profile (28), and/or calculating a volume flow rate (V) with respect to the pressure profile (27) or the reference pressure profile (28), and adjusting (E) at least one process parameter (PP) on the packaging machine (1) taking into account the calculated fill level (22) and/or the volume flow rate (V).