Preform Separation Device with Independent Roller Speed Control
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Solution Overview
Problem
High container throughput in blow molding systems often leads to preform jamming due to inconsistent rotational speeds in existing separating devices, causing operational disruptions and reduced throughput.
Innovation Solution
A separating device with multiple conveyor sections, each with independently operated pairs of counter-rotating conveyor rollers, allowing for adjustable rotational speeds and a control unit to manage these speeds based on occupancy sensors, along with a storage section for fluid-assisted preform transport.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the rotational speed of conveyor rollers is increased to handle high container throughput, then preform removal from container insertion area is improved, but preform buildup and jamming occur in container ejection area
Solution Approach 1:
The conveyor lane is divided into multiple conveyor sections (first conveyor section, second conveyor section, etc.), each with independently operable conveyor rollers. This segmentation allows different sections to operate at different rotational speeds, enabling the system to handle high throughput in some areas while preventing buildup in others, thus resolving the contradiction between productivity and reliability.
Solution Approach 2:
The rotational speeds of the conveyor rollers are made dynamically adjustable rather than constant. The control unit can modify the rotational speed of individual conveyor sections based on real-time occupancy sensor feedback, allowing the system to adapt to varying load conditions and prevent jamming while maintaining high throughput capability.
2Reliability
If the rotational speed of conveyor rollers is reduced to prevent preform jamming, then operation stability is improved, but overall container throughput is reduced
Solution Approach 1:
By segmenting the conveyor into multiple independently controlled sections, the system can maintain high rotational speeds in sections where throughput is needed while using lower speeds in sections where buildup occurs, thus preserving both productivity and reliability simultaneously.
Solution Approach 2:
Different rotational speeds are applied to different local sections of the conveyor lane based on their specific functional requirements. The control unit enables local quality adjustment where each conveyor section can have optimized speed characteristics suited to its position and load conditions.
3Device complexity
If a single conveyor section with constant rotational speed is used, then device complexity is reduced, but the system cannot adapt to varying throughput requirements
Solution Approach 1:
The conveyor system is segmented into multiple sections with independent drive devices, each controllable at different speeds. This segmentation provides the adaptability needed to handle varying throughput requirements while keeping each individual section relatively simple in structure.
Solution Approach 2:
The system enables parameter changes in rotational speed for different conveyor sections based on occupancy detection. The control unit adjusts operational parameters (rotational speed) dynamically to match throughput requirements, providing versatility without requiring complex structural modifications.
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
Enables flexible and trouble-free operation, particularly at high throughputs, by preventing preform buildup and ensuring continuous, efficient separation and transport of preforms.
Implementation Method 1
the preforms remain suspended between the conveyor rollers with their so-called neck ring and are continuously thrown upwards by the counter-rotating conveyor rollers
Data Source
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AI summary
The invention relates to a singulation device for singulating preforms (1) with a conveying lane (6) arranged along a conveying direction (F), wherein at least a first conveying section (7) of the conveying lane (6) is formed by a first pair of conveying rollers (10) with counter-rotating conveying rollers (10a, 10b) whose axes of rotation (D), running essentially parallel to the conveying direction (F), are spaced apart from each other. According to the invention, the conveying lane (6) is formed in a second conveying section (8) arranged downstream of the first conveying section (7) in the conveying direction (F) by a second pair of conveying rollers (12), wherein a drive device (13, 14) is assigned to each of the first and second pairs of conveying rollers (10, 12).