Rotary Vacuum Packaging Carousel for Precise Auto Loading
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Solution Overview
Problem
Current vacuum packaging machines have a large operational footprint and require significant operator interaction for loading, due to limitations in cycle speed and alignment issues caused by stretching endless chains, which complicates the automatic registration and loading of packages.
Innovation Solution
A rotary vacuum chamber system with a single axis of rotation and linear travel portions for platens and vacuum chambers, featuring an automated loading assembly for package alignment and unloading, and a conveying mechanism with a carousel and servo motor for synchronized rotation, along with a transverse sealing mechanism and vacuum chamber lift arms for efficient sealing and evacuation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If a rotary vacuum chamber system with single axis of rotation is used, then the operational footprint is reduced, but the complexity of achieving precise alignment and synchronization increases
Solution Approach 1:
The patent merges the vacuum chamber and platen into a single integrated assembly that rotates together on a single axis. This combination eliminates the need for separate alignment mechanisms between independent vacuum chambers and platens, reducing the operational footprint while managing complexity through integration rather than separate alignment systems.
Solution Approach 2:
The rotating carousel serves multiple functions: it supports multiple platens, provides the rotational motion for sequential processing, and enables automatic indexing to position platens under the vacuum chamber. This multi-functionality reduces the overall system footprint by consolidating what would otherwise require separate mechanisms.
2Extent of automation
If automated loading assembly is implemented, then operator interaction is minimized, but the precision requirements for automatic package registration increase
Solution Approach 1:
The infeed conveyor system positions packages in a predetermined manner before they reach the platen. Guide rails and positioning mechanisms pre-align packages during transport, so that when the automated loading assembly deposits them onto the moving platen, the registration precision requirements are already partially satisfied, reducing the burden on the final positioning mechanism.
Solution Approach 2:
The system uses sensors to detect package position and provides feedback to the control system, which adjusts the timing and position of the automated loading assembly accordingly. This closed-loop control ensures precise registration even with variations in package dimensions or conveyor speed, enabling high-level automation without sacrificing precision.
3Duration of action of stationary object
If chain-driven platens with endless chains are used, then continuous operation is enabled, but chain stretching causes alignment issues over time
Solution Approach 1:
The patent replaces the endless chain drive mechanism with a rotating carousel supported on fixed bearings or a rotary table. This substitution eliminates the stretching problem inherent in flexible chains while maintaining continuous operation capability through the rigid rotational motion of the carousel, which does not degrade over time like stretched chains.
Solution Approach 2:
Instead of using a single continuous chain to drive all platens, the system segments the drive mechanism into individual platen supports mounted on the rigid carousel structure. Each platen is independently positioned by the rigid carousel framework rather than being pulled by a flexible chain, eliminating cumulative stretching errors while allowing continuous rotation and operation.
4Productivity
If multiple vacuum chambers are used for simultaneous processing, then throughput is increased, but the system complexity and space requirements increase
Solution Approach 1:
The patent merges multiple processing stations into a single rotating carousel assembly where multiple platens are mounted on the same rotating structure. This allows simultaneous processing of multiple packages in different stages (loading, vacuumizing, sealing, unloading) within one integrated system, increasing throughput while containing complexity within a compact modular design rather than requiring separate vacuum chamber systems.
Solution Approach 2:
The system transitions from a linear arrangement of sequential vacuum chambers to a rotational, multi-level carousel configuration. By utilizing the vertical dimension and radial arrangement of platens on the rotating carousel, multiple processing stations are packed into a smaller horizontal footprint, increasing throughput capability without proportionally increasing system complexity or space requirements.
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 reduces the operational footprint, enables automatic and precise loading of packages, and increases throughput by minimizing manual intervention and alignment issues, while maintaining efficient vacuumization and sealing processes.
Implementation Method 1
evacuating air from inside the bag through a bag opening to collapse the bag around the contained food product
Implementation Method 2
heat sealing the bag opening to fully enclose the food product within the bag
Data Source
AI summary
An apparatus for vacuumizing and sealing a package includes a plurality of platens and vacuum chambers, each chamber adapted to mate with a dedicated one of the platens; a conveying system for conveying the platens and chambers along a generally angular path having a single axis of rotation; an automated loading assembly having a linear component and configured to load a package onto each of the platens; an automated unloading assembly having a linear portion and configured to unload a vacuumized, sealed package from each loaded platen onto an outfeed conveyor; and a vacuumizing/sealing system configured to cause relative movement of each chamber/platen pair, along a portion of the angular path, to form therebetween an air-tight enclosure accommodating the package and effect vacuumization and sealing of the package.