Rotating Star Transverse Welder for High Speed Packaging
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Solution Overview
Problem
Existing packaging machines have low yield and production speed due to inefficient welding devices, which either have low activity during the welding cycle or require modifications to handle different product sizes.
Innovation Solution
A high-speed packaging group with a rotating star-like transverse welder device and counter-welder belt system that maintains continuous operation and adaptability to various product sizes by synchronizing welder means with the conveyor belt for extended welding periods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If cyclic welding devices completing elliptical trajectory are used, then the welding device can follow the advancing product, but the yield over one welding cycle is low because the device only welds for a brief period while spending most time moving
Solution Approach 1:
The welding device is segmented into multiple welding elements (first welding element, second welding element, third welding element) arranged at different positions along the conveyor path. Each element independently welds a portion of the packaging film as products pass by, allowing continuous welding operations without the need for a single device to complete full elliptical trajectories. This segmentation enables parallel welding operations, significantly increasing the welding yield per cycle.
2Productivity
If vertical welding devices with rectilinear movements are used, then the welder does not need to carry out horizontal movements, but the production speed must be reduced or products must stop at the welding device
Solution Approach 1:
The welding elements are positioned to receive products that are already advancing on the conveyor belt. The packaging film is fed and positioned such that it automatically presents the welding area to each welding element in sequence as products move along the conveyor. This self-service arrangement eliminates the need for products to stop or for welding devices to perform complex horizontal movements, maintaining high production speed while enabling continuous welding operations.
3Productivity
If tank-type welding devices allowing continuous product advancement are used, then welding operations can occur over extended periods, but the devices cannot package different size products without long modification and substitution operations
Solution Approach 1:
The welding elements are positioned at different locations along the conveyor path, allowing their effective welding zone to dynamically adapt to products of varying lengths. The packaging film feed mechanism and welding element positioning can be adjusted to accommodate different product sizes without requiring complete device substitution. This dynamic arrangement enables continuous welding operations while maintaining versatility for packaging various product dimensions.
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 high-speed packaging with continuous welding operation and secure sealing of products of varying sizes without the need for extensive machine modifications, improving production efficiency and versatility.
Implementation Method 1
the welder means (23) cooperate in quick succession with the counter-welder belt (18) in order to weld together two portions of plastic film (17, 17')
Data Source
AI summary
A packaging group that packages products at a high speed when the products are fed in succession in accordance with a predefined and variable pitch is provided. The packaging group includes a conveyor of the products, at least one roll of at least one plastic film, a feed mechanism that feeds the at least one plastic film from the at least one roll respectively atop and underneath the products substantially upon exiting the conveyor, a counter-welder belt downstream of the conveyor which receives the products covered on their upper and lower parts with the at least one plastic film, and a transverse welder device at the counter-welder belt. The transverse welder device includes a rotating star-like structure equipped with at least three spokes provided at their tips with welder mechanisms cooperating one after the other in succession with the counter-welder belt, in order to weld together portions of the at least one plastic film between the products advancing on the counter-welder belt.