Rotatable Wheel Aligner for Tube Insertion into Filter Flow
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Solution Overview
Problem
The manual insertion of elongated objects, such as tubes, into a continuous flow of filter material for producing hollow filters is slow and inaccurate, leading to high rejection rates and reduced productivity in filter manufacturing.
Innovation Solution
A method and apparatus that aligns elongated objects with their longitudinal axes parallel to each other, using a rotatable wheel to move them into a delivery channel, where their insertion speed is regulated to match the flow of material, ensuring efficient and continuous integration into the filter material stream.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual insertion of tubes into filter material flow is used, then operator control is maintained, but manufacturing speed decreases and rejection rate increases
Solution Approach 1:
The system uses sensors to automatically detect tube position and flow material speed, with the control unit autonomously adjusting insertion parameters without operator intervention, achieving both high speed and high accuracy through automated self-regulation
Solution Approach 2:
The manual mechanical insertion process is replaced with an automated system combining sensors, control units, and automated insertion mechanisms that can precisely control insertion speed and positioning, eliminating the trade-off between manual control and automation performance
2Productivity
If automated high-speed insertion is implemented, then productivity increases, but insertion precision may deteriorate
Solution Approach 1:
Sensors continuously monitor tube position, orientation, and flow material speed, providing real-time feedback to the control unit which adjusts insertion parameters dynamically, ensuring high precision even at increased insertion speeds
Solution Approach 2:
The insertion system dynamically adapts its parameters based on real-time conditions, adjusting insertion speed and positioning according to the actual state of the flow material and tube arrangement, allowing optimized performance across varying production rates
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 approach significantly increases the speed and accuracy of inserting elongated objects into the filter material flow, reducing waste and maintaining the processing speed of the filter maker, thereby enhancing productivity and reducing the rejection rate.
Implementation Method 1
moving the elongated objects along a direction parallel to their longitudinal axis in a single line path from the transfer chamber to a delivery channel by a rotatable wheel, the rotatable wheel being arranged adjacent the transfer chamber and adapted to move the elongated objects located in the transfer chamber by contacting the elongated objects with a peripheral surface of the rotatable wheel
Data Source
AI summary
The invention relates to a method for introducing elongated objects defining a longitudinal axis into a continuous flow of material, the method comprising the steps of: —providing a reservoir for holding the elongated objects to be introduced into the continuous flow of material; —introducing the elongated objects from the reservoir into a transfer chamber that is arranged such that the objects are aligned therein with their longitudinal axis parallel to each other; —moving the elongated objects along a direction parallel to their longitudinal axis in a single line path from the transfer chamber to a delivery channel by a rotatable wheel, the rotatable wheel arranged adjacent the transfer chamber and adapted to move the elongated objects located in the transfer chamber by contacting the elongated objects with a peripheral surface of the rotatable wheel; —inserting the elongated objects from the delivery channel to a location where the elongated objects are to be introduced into the continuous flow of material; and —regulating an insertion speed of insertion of the elongated object from the delivery channel to a location where the elongated objects are to be introduced into the continuous flow of material on the basis of a speed of the continuous flow of material at the location in which the elongated object is to be introduced.