Proportional Controller for Packaging Machine Pressure Control
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Solution Overview
Problem
Conventional packaging machines lack reproducibility in pressure control, leading to inconsistent pack shapes and foils, and manual systems often result in late back pressure buildup, causing pack swelling, especially in small chambers.
Innovation Solution
The implementation of a proportional controller that electronically controls pressure across various stations, including forming and sealing, allowing for precise and reproducible pressure settings, eliminating the need for separate valves and pressure controllers, and enabling a gentle initial volume flow followed by a steep increase to prevent bloating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual pressure regulators or proportional controllers are used to control pressure in packaging machines, then pressure can be generated by opening a valve for a predetermined time, but the pressure is subject to fluctuations and there is no reproducibility
Solution Approach 1:
The patent implements a feedback control system where a pressure sensor continuously monitors the actual pressure in the chamber and feeds this information back to the controller. The controller compares the actual pressure with the target pressure and dynamically adjusts the valve opening to maintain the desired pressure, ensuring reproducibility across different pack shapes and foils.
Solution Approach 2:
The patent replaces manual mechanical pressure regulators with an electronic control system that uses a microprocessor-based controller, electronic valve control, and digital pressure sensing. This substitution of mechanical systems with electronic control enables precise, reproducible pressure management while eliminating manual adjustment errors.
2Ease of operation
If manual pressure regulators are used for gassing packs, then pressure control is simplified, but back pressure builds up too late for quick control process, causing the pack to swell
Solution Approach 1:
The patent maintains continuous pressure monitoring and control during the gassing process. The pressure sensor continuously detects pressure changes, and the controller continuously adjusts the valve to maintain the desired back pressure, ensuring immediate response to pressure variations and preventing pack swelling throughout the entire gassing operation.
Solution Approach 2:
The patent replaces slow-responding manual pressure regulators with an electronic control system featuring a fast-acting controlled valve and real-time pressure sensing. This electronic system responds immediately to pressure changes, providing the quick back pressure control needed to prevent pack swelling during rapid gassing operations.
3Reliability
If conventional proportional regulators are used, then pressure control is attempted, but they cannot fully open the valve at the start of regulation due to risk of increasing pressure too much, making them too slow
Solution Approach 1:
The patent implements a two-stage pressure control strategy. In the first stage, the valve is fully opened to rapidly build up pressure. Once the pressure approaches the target value, the controller transitions to the second stage where it modulates the valve opening to precisely maintain the target pressure. This preliminary full-opening action enables fast pressure build-up without compromising safety.
Solution Approach 2:
The patent uses periodic control cycles where the controller continuously monitors pressure and adjusts the valve in discrete control intervals. During each control cycle, the controller determines whether to fully open the valve for rapid pressure build-up or to modulate it for precise pressure maintenance, creating a periodic control pattern that balances speed and safety.
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 ensures consistent pressure throughout the packaging process, preventing pack swelling and allowing for automatic storage and retrieval of required pressure values, enhancing reproducibility and quality control while reducing the risk of material overload.
Implementation Method 1
a heating plate (22) provided in the upper chamber part (23b)
Implementation Method 2
A proportional controller (24, 25) is connected upstream of each compressed air supply (26a, 26b)
Implementation Method 3
Both the lower chamber part (23a) and the upper chamber part (23b) are each connected to a compressed air supply (26a or 26b)
Data Source
Figure 1~2
Figure 3~4a
Figure 4b
AI summary
Packing machine (1) comprises working stations (2) in which the pressure and/or the volume stream is controlled using a proportional controller (24, 25). An independent claim is also included for a method for the production of packages from a film in a packing station. Preferred Features: The proportional controller comprises a valve and an electronic control unit. The controller is connected to a machine control unit (28) for receiving and regulating a prescribed pressure theoretical value.