Pouch Manufacturing with Laser Cutting and Optical Positioning
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Solution Overview
Problem
Existing manufacturing machines for producing pouches with loose products, such as snus pouches, are limited to rectangular shapes and lack flexibility in size changes, compromising productivity and quality.
Innovation Solution
A manufacturing machine and method that utilizes forming conveyors with pockets to create non-rectangular pouches, incorporating heat sealing, laser cutting, and optical control for precise positioning and quality assurance, enabling production of pouches with varied shapes and high efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional FFS manufacturing process with integrated cutting unit is used, then rectangular pouches can be produced efficiently, but the machine lacks flexibility for producing pouches with different shapes and sizes
Solution Approach 1:
The cutting function is extracted from the integrated cutting unit and separated into an independent laser cutting unit. This allows the forming conveyors to focus on creating diverse pouch shapes while the laser cutting unit independently handles various cutting patterns, thereby increasing pouch shape variety without significantly complicating the overall machine structure.
Solution Approach 2:
The laser cutting unit serves as a universal cutting solution that can handle multiple pouch shapes and sizes through software control, replacing the need for dedicated mechanical cutting tools for each shape. This multi-functional approach enables production of various pouch configurations using a single cutting mechanism.
2Manufacturing precision
If mechanical cutting with blades is used in integrated cutting unit, then cutting speed is sufficient for production, but cutting precision and quality are limited
Solution Approach 1:
The mechanical blade cutting system is replaced with a laser cutting system. The laser cutting unit uses optical energy to cut the wrapping material band, providing superior cutting precision and edge quality compared to mechanical blades, while maintaining high production speed through rapid laser scanning and no physical contact with the material.
3Shape
If forming conveyors with pockets are used to create non-rectangular pouches, then pouch shape diversity is improved, but positioning precision and quality control become more challenging
Solution Approach 1:
An optical control unit with sensors is implemented to provide real-time feedback on the position and shape of pouches as they are formed by the forming conveyors. This feedback system enables precise positioning control and quality monitoring, ensuring that diverse pouch shapes are produced with consistent precision and quality standards.
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 solution allows for the production of pouches with diverse shapes while maintaining high productivity and quality, with precise cutting and real-time quality control, ensuring efficient operation and reduced waste.
Implementation Method 1
a laser cutting unit configured to cut out the pouches from the two wrapping material bands
Implementation Method 2
a heat sealing unit configured to seal the two wrapping material bands to each other in a sealing area
Data Source
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AI summary
A manufacturing machine (6) and a manufacturing method for the production of pouches (1), each containing a quantity (2) of a loose product. The following are provided: a first feeding unit (11) configured to feed a wrapping material band (12); a second feeding unit (14) configured to feed the quantities (2) of loose product; a wrapping system, which forms the wrapping material band (12) so as to make the pouches (1); a conveying device (15), which is arranged downstream of the wrapping system and is configured to move the wrapping material band (12) containing the pouches (1) along a moving direction (D); a cutting unit (16), which is arranged along the conveying device (15) and is configured to at least partially cut out each pouch (1) within the wrapping material band (12); an inspection unit (22), which is arranged in an inspection station (S3) upstream of the cutting unit (16) and is configured to capture an image (23) of at least one pouch (1) coupled to the wrapping material band (12); and a control unit (24) configured to determine a position, along the moving direction (D), of the pouch (1) located in the inspection station (S3) by analysing the image (23).