Pneumatic Actuator Synchronization for Softgel Encapsulation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing encapsulation machines for producing soft gelatin capsules face challenges such as limited synchronization of components, mechanical gear changes required for adjustments, potential for premature die wear, contamination of lubricating oil, and complex cleaning processes when switching fill materials.
Innovation Solution
The development of an encapsulation machine with adjustable synchronization between components without gear changes, using pneumatic actuators for pressure control, and a separate drive mechanism to reduce contamination and simplify cleaning, along with a system for encapsulating smaller capsules within larger softgel capsules.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If mechanical gears are used for synchronization of encapsulation machine components, then synchronization can be achieved, but gear changes are required for adjustments and this increases device complexity and maintenance time
Solution Approach 1:
The patent replaces the mechanical gear-based synchronization system with a pneumatic actuator system. The pneumatic actuators control the positioning and operation of dies and other components through air pressure, eliminating the need for mechanical gear changes while maintaining reliable synchronization of the encapsulation process
Solution Approach 2:
The invention specifically employs pneumatic actuators to provide controlled movement and positioning of encapsulation machine components. This pneumatic system allows for easy adjustment of synchronization parameters through air pressure control, replacing complex mechanical gear systems and reducing maintenance requirements
2Manufacturing precision
If pneumatic actuators are used for pressure control, then precise synchronization and adjustment are achieved, but the system requires more complex control mechanisms
Solution Approach 1:
The patent uses pneumatic actuators with adjustable air pressure to achieve precise control over die positioning and component synchronization. The pneumatic system provides smooth, controlled movement with easily adjustable pressure levels, offering precise manufacturing control without the complexity of mechanical gear trains
3Object-affected harmful factors
If a separate drive mechanism is implemented, then contamination of lubricating oil is reduced, but the device structure becomes more complex
Solution Approach 1:
The patent separates the drive mechanism into independent sections, with pneumatic actuators positioned away from the lubricating oil reservoirs. This segmentation prevents contamination of the lubricating oil by pneumatic system components, as the air-driven mechanisms do not require oil lubrication and can be isolated from oil-filled areas
Solution Approach 2:
The pneumatic actuators serve as an intermediary between the control system and the mechanical components, transmitting force through compressed air rather than direct mechanical contact. This intermediary approach prevents the transfer of contaminants to the lubricating oil while still providing effective drive functionality
4Object-affected harmful factors
If complex cleaning processes are used when switching fill materials, then thorough cleaning is achieved, but production time is lost and productivity decreases
Solution Approach 1:
The replacement of mechanical gear systems with pneumatic actuators simplifies the overall machine structure, making cleaning procedures less complex and faster. The pneumatic components have fewer crevices and moving parts that require thorough cleaning, allowing for quicker changeover between different fill materials
Solution Approach 2:
The design of the pneumatic actuator system incorporates easy-access components and surfaces that can be quickly cleaned before switching between different fill materials. The simplified structure allows for preliminary cleaning actions to be performed rapidly, minimizing production downtime while ensuring thorough cleaning
Data Source
AI summary
The present invention provides an apparatus and process for making softgel capsules having incorporated therein other solid dosage forms selected from the group consisting of pellets, smaller capsules, smaller tablets, sustained release solid dosage forms, immediate release solid dosage forms, extended release solid dosage forms and zero order release solid dosage forms, said apparatus comprising: (a) two spreader boxes; (b) two casting drums; (c) a pair of rotary dies having means for suction; (d) a liquid fill system; (e) a wedge for heating gelatine ribbons and feeding said fill; and (f) two lateral dispensing devices said lateral dispensing devices including hoppers having said solid dosage forms, channel guides for transporting said solid dosage forms and a grasping claw for dispensing said solid dosage form into the softgel pocket formed in the rotary dies.