PTP Packaging Machine Content Recovery via Suction Control
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Solution Overview
Problem
Conventional PTP packaging machines often waste non-defective contents by incorrectly identifying them as defective and require complex and costly recovery systems, which can damage the contents and complicate the apparatus.
Innovation Solution
A PTP packaging machine with a rotating drum and imaging units that control the sucking state of contents to prevent non-defective items from being filled into defective sheets, allowing only defective contents to be filled into defective sheets and maintaining non-defective contents in a suction state for reuse, eliminating the need for separate recovery devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an inspection unit punches out defective sheet portions and discharges them, then defective PTP sheets are removed from production, but non-defective contents are wasted and production cost increases
Solution Approach 1:
The patent implements a recovery system where non-defective contents are automatically extracted from defective sheet portions using a content extraction unit. The extracted contents are then reused in subsequent filling operations, eliminating waste while maintaining defective sheet removal. This is achieved by identifying defective portions through inspection and selectively recovering viable contents for reuse.
Solution Approach 2:
The inspection unit provides real-time feedback about defective sheet portions to the control unit, which then coordinates the content extraction and reuse process. The system continuously monitors content quality and adjusts filling operations based on inspection results, ensuring non-defective contents are recovered and reused while defective sheets are properly discharged.
2Loss of substance
If a content recovery system is added to extract non-defective contents from defective sheets, then content waste is reduced, but device complexity and cost increase
Solution Approach 1:
The content extraction unit is integrated into the existing filling unit structure, combining multiple functions (filling, extraction, and reuse) into a single coordinated system. The control unit manages both filling operations and content recovery operations, reducing the need for separate independent systems and minimizing overall device complexity.
Solution Approach 2:
The filling unit is designed to perform multiple functions: normal content filling, defective content extraction, and recovered content reuse. This multi-functional approach eliminates the need for dedicated separate equipment for each operation, reducing device complexity while maintaining content recovery capabilities.
3Loss of substance
If contents are suctioned out and recovered from pocket portions, then non-defective contents can be reused, but contents are likely to be damaged and broken
Solution Approach 1:
The system performs preliminary inspection of contents before filling them into pocket portions. By identifying non-defective contents in advance through the inspection unit, the system can selectively recover only those contents that are unlikely to be damaged, preventing damage to viable contents during the recovery process.
Solution Approach 2:
The patent replaces aggressive mechanical extraction methods with a gentler suction-based recovery system. The content extraction unit uses controlled suction to remove contents from pocket portions, reducing mechanical stress and damage risk compared to forceful mechanical removal methods.
4Loss of substance
If a separate content recovery device is provided, then content can be recovered and reused, but apparatus size expansion and cost increase occur
Solution Approach 1:
The content recovery functionality is merged with the existing filling unit structure. The content extraction unit shares space and components with the filling mechanism, and the control unit manages both operations. This integration significantly reduces the additional space required compared to a completely separate recovery system.
Solution Approach 2:
The filling unit is designed as a multi-functional device that performs both normal filling operations and content recovery operations. By making the filling unit universal, the patent eliminates the need for dedicated separate equipment, thereby minimizing apparatus size expansion while maintaining full content recovery capability.
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 configuration effectively prevents waste of non-defective contents, reduces damage, simplifies the apparatus, and lowers costs by ensuring only defective contents are filled into defective sheets, allowing for efficient identification and disposal of abnormalities without additional discharge mechanisms.
Implementation Method 1
a rotating drum having a plurality of sucking portions that are formed in an outer circumference of the rotating drum to suck the content
Data Source
AI summary
A PTP packaging machine includes: a filler that fills a predetermined content into pocket portions formed in a strip-shaped container film; a sealer that is provided on a downstream side of the filler and mounts a strip-shaped cover film to the container film to close the pocket portions and obtain a strip-shaped PTP film including the cover film mounted to the container film; and a puncher that is provided on a downstream side of the sealer and punches out an expected sheet portion of the PTP film that is a region of eventually forming a predetermined PTP sheet and thereby obtain the PTP sheet.