Rotary Feeder for Uniform Coffee Dosing in Filter Pack Production
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Solution Overview
Problem
Existing coffee pod filling machines experience uneven distribution of powdered coffee due to uncontrolled and non-uniform feeding, leading to substandard coffee pods, especially at higher production speeds.
Innovation Solution
A rotary feeder unit with a rotating feed screw and a precompactor mechanism ensures uniform distribution of coffee doses into filter paper impressions by using a sliding precompactor to compact and level out the coffee within the impressions, aided by a dynamic separation mechanism to prevent re-mixing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a sliding reciprocating piston is used to push coffee into impressions, then the feeding mechanism is simple in structure, but the coffee distribution becomes uneven and uncontrolled
Solution Approach 1:
The feeding mechanism is segmented into multiple rotary feeders, each with individual dosing chambers that independently deposit coffee into specific impressions. This segmentation allows precise control over coffee distribution while maintaining structural simplicity through modular design.
Solution Approach 2:
The patent transitions from a static reciprocating piston to dynamic rotary feeders that rotate in synchronization with the conveyor. This dynamic approach enables continuous, controlled coffee dosing with precise positioning, improving distribution uniformity while maintaining operational simplicity.
2Productivity
If the production speed is increased to improve productivity, then more pods can be produced per unit time, but the coffee distribution becomes even more uneven
Solution Approach 1:
The rotary feeders operate continuously in synchronization with the moving conveyor, eliminating the intermittent action of reciprocating pistons. This continuous operation maintains precise coffee distribution control even at high production speeds, as each dosing chamber deposits coffee at the optimal moment in the rotation cycle.
Solution Approach 2:
The dynamic rotary mechanism allows the feeding system to adapt to varying production speeds while maintaining synchronization with the conveyor. The rotational speed can be adjusted to match conveyor speed, ensuring uniform coffee distribution across the full range of operational velocities.
3Ease of operation
If uncontrolled coffee dropping is used to simplify the dosing process, then the feeding mechanism is easier to operate, but the coffee distribution in impressions becomes non-uniform
Solution Approach 1:
The rotary feeders are designed to automatically deposit precise coffee doses into each impression through their rotational motion and synchronized timing with the conveyor. This self-service mechanism eliminates the need for complex control systems or manual intervention, maintaining ease of operation while achieving uniform coffee distribution through precise mechanical design.
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 ensures consistent and uniform coffee distribution within coffee pods, meeting quality specifications even at high production speeds, resulting in improved pod quality and consistency.
Implementation Method 1
the coffee, pushed by the piston element in the feed tube, drops down into the impressions
Implementation Method 2
Vertical, reciprocating pressers are mounted at the feed tube and compress the coffee in the circular impressions
Data Source
AI summary
Described is a unit (1) for feeding powdered infusion material to a machine (M) producing packs (3) made from filter material (5). The machine (M) comprises a production line (2) for making such packs (3) and consists of a conveyor (4) with mobile recesses (7) moving in a feed direction (L) designed to be covered with filter material (5) and to form impressions (8) in the filter material (5); rotary feeders (10) fitted to the unit (1) designed to feed an amount or dose (C) of the powdered infusion material into the impressions (8), and rotary precompactors (14) mounted on the rotary feeders (10) acting together with rotary feeders (10) to distribute the doses (C) uniformly inside the impressions (8).