Reciprocating Paddle Doser Assembly for Consistent Filler Flow
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Solution Overview
Problem
Existing technologies face challenges in efficiently controlling the distribution and level of filler material in manufacturing plant material products, particularly in the formation of pouches, leading to inconsistencies and inefficiencies in the filling process.
Innovation Solution
A doser assembly with a hopper assembly, vibration transmission assembly, and paddle mechanism, coupled with level sensors and PID control loops, to precisely regulate and distribute filler material, ensuring consistent levels and flow rates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a traditional filling mechanism is used, then the device complexity is low, but the manufacturing precision and consistency of filler material distribution are poor
Solution Approach 1:
The patent employs a vibration transmission assembly with an eccentric shaft, connecting rod, and bracket that converts rotary motion into reciprocating motion of the paddle. This mechanical vibration mechanism agitates the filler material in the hopper, ensuring consistent flow and distribution into the pouch, thereby improving manufacturing precision without excessive complexity
Solution Approach 2:
The patent incorporates level sensors that detect the filler material level in the hopper and feed this information to a PID control system. The controller adjusts the operation of the doser assembly based on this feedback, maintaining consistent filler material distribution and level control, which improves manufacturing precision through closed-loop control
2Productivity
If manual or simple automation is used for filling, then the device complexity is low, but the productivity and filling speed are insufficient
Solution Approach 1:
The vibration transmission assembly operates periodically through the reciprocating motion of the paddle, which agitates and distributes filler material at controlled intervals. This periodic action maintains consistent material flow into the pouch, enabling high-speed automated filling while managing system complexity through rhythmic, predictable operations
Solution Approach 2:
The patent replaces manual filling operations with an automated doser assembly that uses a PID control system and level sensors to manage the filling process. This substitution of mechanical automation for manual labor increases productivity and filling speed, though it introduces additional system complexity
3Productivity
If high-speed filling is implemented, then the productivity is improved, but the manufacturing precision and consistency of filler levels deteriorate
Solution Approach 1:
The level sensors continuously monitor the filler material level in the hopper during high-speed operation and provide feedback to the PID controller. This closed-loop control adjusts the dosing mechanism in real-time, maintaining consistent filler material levels even at high filling rates, thus preserving manufacturing precision while achieving high productivity
Solution Approach 2:
The vibration transmission assembly operates at frequencies and amplitudes optimized for high-speed filling while maintaining material flow consistency. The reciprocating paddle motion agitates the filler material to prevent bridging and ensure steady flow into the pouch, enabling high productivity without sacrificing filling precision
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 doser assembly achieves precise control of filler material levels, reducing variations and enhancing the consistency and efficiency of the filling process, thereby improving the quality and reliability of pouch production.
Implementation Method 1
The vibration transmission assembly may include a shaft that is configured to rotate around a central rotation axis, an eccentric that is fixed to the shaft and having a center that is radially offset from the central rotation axis, a connecting rod that is pivotably connected to the center of the eccentric, and a bracket that is pivotably connected to the connecting rod
Data Source
AI summary
A doser assembly includes a hopper assembly configured to receive filler material, a vibration transmission assembly coupled to the hopper assembly, and a paddle in a hopper opening that extends through the hopper assembly. The vibration transmission assembly includes a shaft that is configured to rotate around a central rotation axis, an eccentric that is fixed to the shaft and has a center that is radially offset from the central rotation axis, a connecting rod that is pivotably connected to the center of the eccentric, and a bracket that is pivotably connected to the connecting rod. A first end of the paddle is pivotably coupled to the hopper assembly at a paddle pivot joint. The paddle is fixed to the bracket of the vibration transmission assembly separately from the hopper assembly. The vibration transmission assembly is configured to cause the paddle to reciprocatingly pivot around the paddle pivot joint.