Packaging Web Positioning Using Magnetic Feedback

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing solutions for applying opening devices to packaging materials face challenges in precision positioning due to tolerance errors, which worsen with an increase in the number of moulds, affecting the accuracy of pre-laminated holes relative to moulds and ultimately the packaging process.

Innovation Solution

A unit with a feeding group and magnetic sensors that adjust the position of pre-laminated holes relative to moulds, using intentional offsets to compensate for tolerance errors, allowing for increased moulds without compromising precision, by using magnetic markers and sensors to detect and correct the positions of pre-laminated holes along the advancing direction.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If the number of moulds is increased to apply multiple opening devices, then the productivity is improved, but the manufacturing precision deteriorates due to lengthened tolerance chain

Engineering Contradiction:

Improverate of opening device applicationVSAvoidpositioning accuracy of pre-laminated holes

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent employs magnetic sensors to detect the actual positions of magnetic markers on the web, providing feedback information about positioning deviations. This feedback enables the system to measure and compensate for tolerance errors, allowing multiple moulds to be positioned accurately despite the lengthened tolerance chain that would normally occur with increased productivity.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent replaces traditional mechanical positioning systems with a magnetic field-based positioning system. Magnetic markers embedded in the web interact with magnetic sensors to establish precise positional relationships without relying on mechanical tolerances. This substitution eliminates the cumulative tolerance errors that plague mechanical multi-mould positioning systems.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Device complexity

If traditional mechanical positioning is used for multiple moulds, then the device complexity is reduced, but the measurement precision deteriorates

Engineering Contradiction:

Improvepositioning system structureVSAvoidposition detection accuracy

Core Design Contradiction:

Device complexityVSMeasurement precision

Solution Approach 1:

The patent substitutes complex mechanical measurement and positioning mechanisms with a magnetic field-based system. Magnetic markers and magnetic sensors provide precise position detection without the mechanical complexity of rulers, scales, or mechanical coupling systems. The magnetic field inherently provides the measurement function with superior precision.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces magnetic markers as intermediary elements between the web and the positioning system. These markers serve as mediators that carry positional information through magnetic fields, enabling precise measurement without direct mechanical contact or complex mechanical measurement apparatus.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 precise positioning of multiple pre-laminated holes relative to moulds, maintaining high accuracy and allowing for a higher rate of opening device application without lengthening the tolerance chain, thus enhancing the packaging process efficiency.

Implementation Method 1

using magnetic markers and sensors to detect and correct the positions of pre-laminated holes along the advancing direction

Methodology Applied

Scientific EffectMagnetic field detection: Magnetic Field

Implementation Method 2

A unit with a feeding group and magnetic sensors that adjust the position of pre-laminated holes relative to moulds, using intentional offsets to compensate for tolerance errors

Methodology Applied

Scientific EffectMechanical displacement: Displacement

Data Source

PatentUS10286583B2Unit and a method for carrying out a first operation and a second operation on a web

Publication Date: 2019.05.14 TETRA LAVAL HOLDINGS & FINANCE SA

AI summary

A unit for carrying out operations on first and second areas of packaging material which are spaced a first distance along direction when a portion of packaging material comprising first and second areas is flat; unit comprising: a feeding group feeding a packaging material web along a direction and in a first sense; a first tool to carry out first operation on first area arranged in a first desired position; a second tool to carry out second operation on second area arranged in a second desired position; first and second tool spaced for a second distance along direction; feeding group comprises: advancing device controllable to arrest web in a position, at which second area is spaced an intentional offset from second desired position; and an actuator controllable for moving second area towards second desired position to recover offset; absolute value of difference between first and distances being equal to offset.