Rotary Beverage Filler Detection and Ejection Mechanism
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Solution Overview
Problem
Existing beverage container filling systems face issues with collisions and damage due to large rotating masses and moments of inertia, leading to slow operation and potential system shutdowns when handling errors occur, as they require long stopping distances and low rotational speeds to prevent damage.
Innovation Solution
A system with a detection device that identifies non-transferred containers using mechanical, optical, or acoustic means, coupled with an ejection device to prevent collisions by removing stuck containers and allowing the system to continue operating or stop safely, ensuring precise transfer points and efficient filling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the rotational speed of the filler carousel is increased to improve filling performance, then productivity increases, but the stopping distance increases due to high moments of inertia, leading to longer downtime when shutdowns are required
Solution Approach 1:
The detection device detects non-transferred containers before they cause collisions, and the ejection device ejects them in advance. This preliminary action prevents the need for emergency shutdowns, allowing the system to maintain high rotational speeds for improved productivity while minimizing actual stopping time.
Solution Approach 2:
The detection device continuously monitors the transfer points and provides feedback about non-transferred containers. This feedback enables the control system to activate the ejection device at the appropriate moment, ensuring smooth operation without interruptions that would increase downtime.
2Reliability
If the rotational speed is reduced to allow for shorter stopping distances, then system reliability improves by preventing collisions, but productivity decreases
Solution Approach 1:
The ejection device acts as an intermediary mechanism between the detection device and the filler carousel. When a non-transferred container is detected, the ejection device removes it before it can cause a collision, allowing the system to maintain high rotational speeds without compromising reliability.
Solution Approach 2:
The system replaces the traditional mechanical approach of reducing rotational speed for safety with a detection-and-ejection system. This substitution allows the system to maintain high speeds while ensuring safety through active monitoring and intervention, thereby preserving productivity.
3Device complexity
If a non-transferred container is not detected and removed, then the system structure remains simple, but collisions occur causing damage to system components and requiring shutdowns
Solution Approach 1:
The detection device and ejection device work together to identify and remove non-transferred containers before they can cause collisions. This preliminary action prevents damage to system components and eliminates the need for shutdowns, significantly improving reliability with only moderate increases in device complexity.
4Reliability
If the detection and ejection systems are added to prevent collisions, then reliability improves, but device complexity increases
Solution Approach 1:
The detection device provides continuous feedback about the status of containers at transfer points. This feedback enables the control system to activate the ejection device only when necessary, achieving high reliability with minimal additional complexity. The system adds intelligence rather than substantial mechanical complexity.
Data Source
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AI summary
The plant has stationary anchored and permanently rotating transport and filling system with a defined number of positions for individual beverage containers. A definite transfer point (22) is provided for holding and filling the beverage containers during revolution of the transport and filling system. A detection device (36) is also provided for identifying a beverage container that is not delivered from the rotating transport and filling system to the transfer point (26). An independent claim is included for a method for filling beverage containers.