Rotatable Welding Unit for Vertical Packaging Machines
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Solution Overview
Problem
Existing vertical packaging machines are limited in producing various types of bags from a single plastic material, requiring complex and costly adjustments for different bag types, and struggle to balance high production speed with precise and quality welds, especially when switching between intermittent and continuous modes.
Innovation Solution
A versatile packaging machine with a rotatable second welding unit and interchangeable first welding unit and forming tube, allowing for orthogonal transverse welds and easy replacement, combined with pneumatic or hydraulic balancing means for precise and high-speed operation in both intermittent and continuous modes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the packaging machine operates in intermittent mode to carry out precise and top quality welds, then welding precision is improved, but production speed decreases
Solution Approach 1:
The patent applies dynamics by enabling the packaging machine to switch between intermittent and continuous operating modes. The welding unit and film feed system are designed to dynamically adjust their operation: in intermittent mode, the film is fed in discrete increments with welding occurring when the film is stationary, ensuring high welding precision; in continuous mode, the film feeds continuously while the welding unit performs welds during controlled pauses or at synchronized intervals, maintaining both speed and weld quality
2Productivity
If the packaging machine operates in continuous mode to achieve high production speeds, then productivity is improved, but welding precision deteriorates and device complexity increases
Solution Approach 1:
The system dynamically adjusts the film feed and welding unit operation to maintain precision during continuous mode. The film feed mechanism incorporates controlled pause points or synchronization points where welding occurs, even though the overall film feed continues without interruption. This dynamic coordination allows high production speeds while maintaining weld quality through precise timing and positioning control
3Productivity
If the packaging machine uses complex movement means to carry out synchronized welds in continuous mode, then productivity is improved, but device complexity and cost increase
Solution Approach 1:
The welding unit is designed as a multi-functional device that can perform both longitudinal and transverse welds, and can operate in both intermittent and continuous modes. The film feed system is also designed to accommodate both operating modes with a single configuration. This universality eliminates the need for separate complex movement mechanisms for different welding directions and modes, reducing overall device complexity while maintaining high productivity
4Adaptability or versatility
If the packaging machine requires total replacement of welding units and forming tube to produce different bag types, then adaptability deteriorates, but manufacturing precision for each bag type is maintained
Solution Approach 1:
The patent designs a universal welding unit and forming tube assembly that can produce multiple bag types including pillow bags, square bottom bags, and Doypack bags without requiring total replacement. The welding unit can be reconfigured to perform different welding patterns (longitudinal, transverse, angled) and the forming tube can be adjusted or replaced with interchangeable inserts to accommodate different bag geometries. This multi-functionality maintains manufacturing precision for each bag type while dramatically reducing changeover time and production downtime
5Adaptability or versatility
If the packaging machine uses interchangeable welding units and forming tubes to produce different bag types, then adaptability is improved, but device complexity increases
Solution Approach 1:
The patent applies segmentation by dividing the welding system into modular, interchangeable components: the welding unit is a self-contained module that can be replaced or reconfigured, and the forming tube is segmented into a main body with interchangeable inserts or attachments. Each module is designed with standardized interfaces and mounting mechanisms that simplify replacement and reconfiguration. This segmented architecture improves adaptability for producing different bag types while keeping the complexity of each individual module manageable and the interchange process simple
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
Enables the production of multiple bag types, including 'pillow', 'square bottom', and Doypack bags, with high precision and speed, reducing maintenance needs and production downtime, while maintaining quality welds across different plastic materials.
Implementation Method 1
a first welding unit for carrying out on the film at least a longitudinal weld parallel to a feed direction of the film along the forming tube and a second welding unit for carrying out transverse welds on the film
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
A packaging machine for packaging products in bags (101; 102; 103; 104) comprises a forming tube (2; 12) around which a film (50) made of plastic material is wrapped that is unwound from a reel (51), a feeding unit for dispensing into the forming tube (2; 12) defined doses of product to be packaged in the bags (101; 102; 103; 104), a first welding unit (3) for carrying out on the film (50) at least a longitudinal weld (52; 53), parallel to a feed direction (A) of the film (50) along the forming tube (2; 12), a second welding unit (4) for carrying out on the film (50) transverse welds (54; 55), in particular almost orthogonal to the feed direction (A), mounted rotatably about a rotation axis (Z), in particular substantially parallel to the feed direction (A), so as to carry out transverse welds (54; 55) at least along two welding directions (B, C) that are orthogonal to each other and to the feed direction (A), and moving means (5) for supporting and moving the second welding unit (4) along the feed direction (A) with a reciprocating rectilinear motion; moving means (5) comprises a carriage (6), supporting the second welding unit (4) and slidingly connected to the supporting frame (7) of the machine (1), actuating means (10) to move the carriage (6) and balancing means (11) to cooperate with actuating means (10) for moving said carriage (6); the balancing means (11) comprises at least a cylinder (21) that is in flowing connection with a reservoir (22) of pressurised air and fixed to the supporting frame (7) and connected with and acting on the carriage (6).