Soft Capsule Injection Control via Piston Servo Mechanism
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Solution Overview
Problem
Conventional soft capsule manufacturing apparatuses face challenges in achieving precise control over the injection amount, interval, and rate of core solution due to the complexity of precise rotation and operation of die rolls and core solution injection, which limits effective drug dosage control.
Innovation Solution
A soft capsule manufacturing apparatus equipped with an injection controller that utilizes the cyclic movement of a piston and operation of a 3-way solenoid valve, automatically adjusted and controlled by a control panel processing signals from detection sensors, to manage the injection amount, interval, and rate of core solution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional die rolls and core solution injection mechanism are used, then soft capsule manufacturing is achieved, but precise control over injection amount, interval, and rate cannot be easily achieved
Solution Approach 1:
The patent replaces the conventional mechanical die roll rotation system with a piston-cylinder mechanism driven by a servo motor. This substitution allows for more precise control of the injection amount through the piston's linear movement, which can be accurately controlled by the servo motor's rotation-to-linear-motion conversion, thereby improving injection precision while reducing operational complexity.
Solution Approach 2:
The patent introduces multiple controllable parameters including injection amount (via piston movement distance), injection interval (via servo motor timing), and injection rate (via piston speed control). By independently adjusting these parameters, the system achieves precise control over the core solution injection process without requiring complex mechanical synchronization of multiple rotating components.
2Manufacturing precision
If precise rotation and operation of die rolls is required, then core solution injection is achieved, but uniformed amount of core solution cannot be easily achieved
Solution Approach 1:
The patent replaces the complex rotational mechanics of die rolls with a linear piston movement system. The servo motor converts rotational motion to precise linear piston displacement, making it easier to control the exact amount of core solution injected. This substitution simplifies the operation while ensuring uniform injection amounts through programmable piston stroke length.
Solution Approach 2:
The system incorporates sensors that automatically detect the presence of gelatin sheets and trigger the injection process. The control system automatically adjusts injection parameters based on sensor feedback, eliminating the need for manual intervention in timing and dosage control, thereby achieving uniform injection amounts with ease of operation.
3Extent of automation
If conventional injection control is used, then drug injection is achieved, but control of injection interval and injection rate is not achieved
Solution Approach 1:
The patent incorporates sensors that detect the position of gelatin sheets and provide feedback to the control system. Based on this feedback, the control system automatically adjusts the injection timing (interval) and piston movement speed (rate) to ensure precise delivery of the core solution. This closed-loop control system achieves comprehensive automation while maintaining precise control over all injection parameters.
Solution Approach 2:
The system dynamically adjusts injection parameters in real-time based on operational conditions. The servo motor can vary its speed and the piston's movement rate according to the detected gelatin sheet position and processing speed, enabling automatic control of injection interval and rate while maintaining accurate dosage delivery under varying operational conditions.
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 solution enables efficient control over the injection of core solution, ensuring consistent and precise dosage, improving the manufacturing process by automating the adjustment and operation of the injection controller.
Implementation Method 1
said injection controller controls an injection amount, an injection interval and/or an injection rate of core solution, using the cyclic movement of piston
Implementation Method 2
the operation of 3-way solenoid valve
Implementation Method 3
a servo motor for producing pivot rotation
Implementation Method 4
a pivot rotation gear for transferring pivot rotation to the piston located on inner part of cylinder
Data Source
AI summary
A soft capsule manufacturing apparatus for controlling an injection amount, an injection interval and/or an injection rate of core solution by an injection controller, wherein the operation of the injection controller is automatically adjusted and controlled by a control panel, after processing the signal from the detection sensor for checking the injection status.