Pouch Manufacturing Machine Real-Time Weight Inspection
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Solution Overview
Problem
Existing machines for manufacturing nasal or oral snuff pouches suffer from high reject rates due to batch sampling for weight checking, where correct pouches are discarded along with defective ones, and production defects are not immediately identified, as measurements are based on samples rather than individual products.
Innovation Solution
A machine that incorporates a microwave emitter device to check the mass density of each pouch in real-time, connected to a master control unit for immediate weight calculation and comparison against reference values, allowing for in-line rejection of defective pouches and automatic correction of feed mechanisms without halting production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If batch sampling is used for weight checking, then the measurement process is simple, but the reject rate increases and production efficiency decreases
Solution Approach 1:
The patent replaces manual batch sampling and weighing with an automatic optical inspection system that uses cameras and image processing to measure pouch dimensions and calculate weight non-contactly. This substitution eliminates the need to stop production for sampling and prevents rejection of correctly weighted pouches in defective batches.
Solution Approach 2:
The patent introduces an intermediary calculation method where pouch weight is derived from dimensional measurements taken by optical sensors rather than direct weight measurement. This allows individual pouch assessment without physical contact or production interruption.
2Reliability
If batch sampling is used for defect identification, then the inspection process is simple, but defects are not immediately identified and correct pouches are discarded
Solution Approach 1:
The patent performs preliminary inspection of each pouch individually as it passes through the production line, before the batch is complete. This allows immediate identification of defective pouches and prevents them from being mixed with good pouches, eliminating the need to reject entire batches.
Solution Approach 2:
The patent replaces physical weighing and manual inspection with optical sensing and automated image analysis. This allows non-contact, individual pouch assessment that provides immediate defect identification without the lag and error inherent in batch sampling methods.
3Device complexity
If manual sampling and weighing is performed, then the equipment complexity is low, but the production line must be stopped for adjustments
Solution Approach 1:
The patent implements continuous inspection throughout the production process, with the optical scanning system operating alongside the running production line. This eliminates stoppages for quality checks and allows immediate detection and correction of feed mechanism issues without halting production.
Solution Approach 2:
The patent replaces manual weighing equipment and operations with automated optical measurement systems that integrate into the existing production line. This substitution eliminates the need for manual intervention and production stoppages, enabling continuous operation and real-time quality monitoring.
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 solution enables precise, real-time weight checking of every pouch, significantly reducing reject rates and allowing for immediate defect correction, ensuring high efficiency and precision in production with minimal rejects.
Implementation Method 1
a microwave emitter device to check the mass density of each pouch in real-time
Data Source
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AI summary
Pouches (2) of cohesionless material, typically a smokeless tobacco product, are manufactured on a machine equipped with feed components (101) by which the material is supplied to a conveyor (4) at a delivery station (8), then transferred by the conveyor (4) from this station (8) to a transfer station (9) where a forcing mechanism (14) directs measured portions (100) of the material from the conveyor into at least one duct (12) connecting with a form- fill-and-seal wrapping station (10) where the portions (100) are enclosed in a continuous succession (21) of pouches (2). Before being separated one from the next at a downstream cutting station (23), the single pouches (2) pass through an in-line quality control station (105) at which their weight is checked individually.