Thermoforming Packaging Machine Sealing Station Positioning

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Solution Overview

Problem

Thermoforming packaging machines face inefficiencies in film consumption due to irregular film shrinkage and tolerances during feed movements, leading to excessive foil waste and generous pack web designs.

Innovation Solution

A thermoforming packaging machine with a measuring system that determines the position of reference elements in the lower film before the sealing station, allowing precise positioning of the sealing station relative to the formed troughs, reducing the need for wide pack edges and minimizing film waste by accounting for inaccuracies in film positioning.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the sealing station is positioned with generous margins to account for film shrinkage and feed tolerances, then sealing quality is maintained, but film consumption increases due to larger pack web widths

Engineering Contradiction:

Improvesealing qualityVSAvoidfilm waste

Core Design Contradiction:

ReliabilityVSLoss of substance

Solution Approach 1:

A reference element is introduced into the lower film before the forming station in a predetermined position relative to where the troughs will be formed. This allows the measuring system to detect the reference element and calculate the actual position of the troughs in advance, enabling precise positioning of the sealing station before the sealing operation occurs.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The measuring system detects the position of the reference element in the lower film and provides feedback to the control system. The control system uses this information to dynamically adjust the position of the sealing station via the adjustment device, ensuring precise alignment with the actual trough positions rather than relying on fixed generous margins.

Inventive Principle:

Principle #23Feedback

2Manufacturing precision

If the position of the reference element is determined during feed movement, then real-time positioning is achieved, but detection inaccuracies occur due to dynamic movement

Engineering Contradiction:

Improvepositioning accuracyVSAvoidreference element detection accuracy

Core Design Contradiction:

Manufacturing precisionVSMeasurement precision

Solution Approach 1:

The feed chains perform periodic intermittent feed movements, bringing the lower film and formed troughs to a standstill at regular intervals. The measuring system is configured to detect the reference element specifically during these standstill phases, when positioning accuracy is maximized and detection is most reliable.

Inventive Principle:

Principle #19Periodic action

Data Source

PatentEP2740672B2Deep draw packaging machine with clock cycled positioning of a sealing station and corresponding method

Publication Date: 2020.01.22 MULTIVAC SEPP HAGGENMULLER GMBH & CO KG

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AI summary

The machine has forming station to form trays into base film, and device to introduce reference element into base film. Adjustment device is provided to adjust position of sealing station (9) along production direction and displacement measuring device (26). Measuring system is set within feed length upstream of sealing station to determine position of reference element. Control unit is provided to control position of sealing station based on location of reference element relative to trays. Machine main portion is operated intermittently with feed length for every work cycle. An independent claim is included for a method for operating thermo-forming packaging machine.