Rotary Compound Tank Assembly for Accurate Level Sensing
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Solution Overview
Problem
Conventional rotary liner machines face speed limitations and maintenance issues due to compound bridging between level sensors and centrifugal force affecting level measurement accuracy, requiring frequent disassembly and cleaning.
Innovation Solution
A rotary tank assembly with a single guide pulse level sensor and a smaller diameter compound tank, coupled with a rotary union assembly, eliminates the need for multiple sensors and reduces centrifugal effects, allowing for continuous operation and increased rotational speed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If multiple level sensors are used to measure compound level in the tank, then measurement coverage is improved, but compound bridging between sensors increases causing electrical current pathways and measurement errors
Solution Approach 1:
The patent extracts the problematic intermediate elements (multiple level sensors) from the system. By using a single level sensor positioned at the appropriate height, the invention eliminates the compound bridging issue that occurs between multiple sensors while maintaining adequate measurement capability.
Solution Approach 2:
The patent introduces a non-conductive barrier or coating as an intermediary between the level sensor and the compound. This mediator prevents electrical current pathways formed by compound bridging while allowing the sensor to continue measuring the compound level accurately.
2Productivity
If tank rotational speed is increased to improve production volume, then productivity increases, but centrifugal force causes compound to flow outward affecting level measurement accuracy
Solution Approach 1:
The patent removes the mechanical insert that was previously used to arrest compound flow. Instead, it relies on the single level sensor positioned to account for the centrifugal flow pattern, simplifying the system while maintaining measurement accuracy at high rotational speeds.
Solution Approach 2:
The patent changes the measurement approach by positioning the single level sensor at a specific height that accounts for the centrifugal force-induced compound level variation. This parameter adjustment allows accurate measurement despite the compound flowing outward at high rotational speeds.
3Measurement precision
If three level sensors are used to detect empty, full, and overflow levels, then measurement coverage is improved, but device complexity and maintenance requirements increase
Solution Approach 1:
The patent extracts two of the three level sensors from the system, retaining only a single level sensor. This reduction simplifies the sensor assembly while the sensor is positioned to provide adequate measurement coverage for the application requirements.
Solution Approach 2:
The single level sensor is positioned and configured to perform multiple measurement functions that previously required three separate sensors, providing a universal solution that reduces complexity while maintaining measurement capability.
4Measurement precision
If tank diameter is reduced to minimize centrifugal effects, then measurement stability is improved, but tank volume decreases affecting compound capacity
Solution Approach 1:
The patent changes the measurement parameter by using a single level sensor positioned at a specific height that compensates for centrifugal effects. This allows the tank to maintain its larger diameter for adequate compound capacity while achieving measurement stability through the adjusted sensor positioning rather than reducing tank size.
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 provides reliable operation, increased production volume, and consistent compound level measurement, reducing maintenance needs and improving operational efficiency by minimizing compound bridging and fluid dynamics issues.
Implementation Method 1
a sensor assembly (210) adapted to measure the level of compound (300) within the compound tank (202)
Implementation Method 2
a rotary union assembly (220) structured to pivotally couple the fill tube (204) and the sensor assembly (210) to the compound tank (202)
Implementation Method 3
as the tank assembly rotates (e.g., about 180-262.5 rpm), the compound is impacted by the induced centrifugal force, which causes it to flow outward toward the walls of the tank such that the compound rises up the wall on the exterior of the tank
Data Source
AI summary
A rotary tank assembly is provided for a liner. The liner is structured to apply a compound to a plurality of container closures. The rotary tank assembly includes a compound tank, a fill tube structured to fill the tank with a volume of the compound to a desired level, a sensor assembly adapted to measure the level of the compound within the compound tank, and a rotary union assembly structured to pivotably couple the fill tube and the sensor assembly to the compound tank. The sensor assembly only requires one single probe.