Spirofeed Brush Box Gear System for Blister Filling
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional blister machine brush boxes are inefficient at filling depressions on blistered sheets at increased speeds, leading to empty packages and high rejection rates, and are not suitable for uncoated pharmaceuticals due to damage and dust issues, resulting in operational and maintenance challenges.
Innovation Solution
A brush box with a gear system enabling spirographic movement of distributing means, including brushes and flaps, coupled with an electric motor and dust collection system, for efficient and controlled distribution of products into blister sheet cavities, with adjustable height and motor control for improved reliability and reduced size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the speed of the blistered sheet is increased, then productivity is improved, but the filling efficiency deteriorates leading to empty depressions and high rejection percentage
Solution Approach 1:
The brush box is designed with adjustable brush pressure and rotation speed that can be dynamically modified to match different sheet speeds. The brush assembly includes adjustable arms that allow operators to optimize the agitation force at varying production rates, ensuring reliable filling even at high speeds.
Solution Approach 2:
The system allows changing operational parameters such as brush rotation speed, brush pressure, and brush position to optimize filling efficiency at different sheet speeds. This parameter adjustability ensures that filling reliability is maintained across the full range of productivity levels.
2Reliability
If multiple brushes are incorporated to sweep over each corner of the blistered sheet, then filling efficiency is improved, but the size and weight of the brush box increases requiring bigger drives
Solution Approach 1:
The brush assembly is designed as a multi-functional unit that can serve multiple corners and sections of the blistered sheet simultaneously. The adjustable brush arms can be positioned to cover different areas, allowing a single brush assembly to perform the work of multiple fixed brushes, thereby reducing overall system size.
Solution Approach 2:
The brush assembly incorporates movable and adjustable components that allow dynamic repositioning of brushes to cover different sheet areas. This dynamic configuration replaces the need for multiple fixed brush assemblies, reducing the overall size and weight of the brush box while maintaining comprehensive coverage.
3Productivity
If rotary brushes are used to agitate uncoated pharmaceutical products, then filling efficiency is improved, but product damage increases and dust is generated
Solution Approach 1:
The brush system incorporates brushes with different local properties - softer brush materials are used specifically for uncoated pharmaceutical products, while harder brushes can be used for coated products. This localized adaptation of brush quality ensures efficient filling while minimizing damage and dust generation for sensitive uncoated products.
Solution Approach 2:
The system allows changing brush parameters such as material hardness, brush density, and rotation speed based on the type of product being processed. For uncoated pharmaceuticals, softer brushes with lower rotation speeds are selected to reduce mechanical stress and dust generation, while maintaining adequate filling efficiency.
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
Enhances packaging efficiency, reduces maintenance costs, and effectively handles both coated and uncoated pharmaceuticals by minimizing damage and dust, leading to improved product quality and operational simplicity.
Implementation Method 1
a gear system configured inside the housing. The gear system includes a ring shaped first gear having a plurality of first teeth configured circumferentially on an inner side of the first gear. At least one second gear configured inside the first gear, the at least one second gear having a plurality of second teeth that engages with the plurality of first teeth such that the first gear is configured to rotate about its axis when the at least one second gear moves on the inner side of the first gear
Data Source
AI summary
The present disclosure relates to a brush box that includes a housing, a gear system (100) configured inside the housing. The gear system (100) includes a first gear (102) having first teeth configured on an inner side of the first gear (102). Second gear (104) configured inside the first gear (102), the second gear (104) includes second teeth that engages with the first teeth such that the first gear (102) configured to rotate about its axis when the at least one second gear (104) moves on the inner side of the first gear (102). Distributing means (106) operatively coupled to the second gear (104). The movement of the second gear (104) circumferentially on the inner side of the first gear (102) enables spirographic movement of the distributing means (106) around a centre of the first gear (102).