Sprayer Pump Insertion Alignment via Preliminary Straightening

Solution Overview

Problem

Automatic capping machines struggle to accurately insert sprayer pumps into bottles due to the bending of the pump tube, which often misses the bottle opening, leading to manual labor or expensive complex machinery being necessary for accurate insertion.

Innovation Solution

A packaging system that includes a conveyor, a cap transfer rake, a diptube assembly, a turn-belt, and a retractable stop to align and straighten the sprayer pump tube for precise insertion into the bottle, allowing for automatic and efficient capping.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If automatic capping machines are used to insert sprayer pumps into bottles, then productivity is improved, but manufacturing precision deteriorates due to tube bending causing misalignment

Engineering Contradiction:

Improveautomatic insertion speedVSAvoidinsertion accuracy

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The system performs preliminary straightening of the diptube using a roller mechanism before the insertion operation. The roller applies controlled pressure to the bent tube section, pre-correcting its alignment so that when the sprayer pump is inserted, the tube naturally follows the correct path into the bottle opening, thereby maintaining both speed and precision

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

A guide rod or alignment fixture acts as an intermediary element between the sprayer pump assembly and the bottle opening. This intermediary component provides a physical pathway that forces the diptube into proper alignment during insertion, compensating for bends in the tube while maintaining automated high-speed operation

Inventive Principle:

Principle #24Intermediary (Mediator)

2Device complexity

If simple automated equipment is used for sprayer insertion, then device complexity is reduced, but manufacturing precision deteriorates due to inability to correct tube bending

Engineering Contradiction:

Improveinsertion mechanism complexityVSAvoidtube alignment accuracy

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

The system performs preliminary straightening of the diptube using a roller mechanism before the insertion operation. The roller applies controlled pressure to the bent tube section, pre-correcting its alignment so that when the sprayer pump is inserted, the tube naturally follows the correct path into the bottle opening, thereby maintaining both speed and precision

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

A guide rod or alignment fixture acts as an intermediary element between the sprayer pump assembly and the bottle opening. This intermediary component provides a physical pathway that forces the diptube into proper alignment during insertion, compensating for bends in the tube while maintaining automated high-speed operation

Inventive Principle:

Principle #24Intermediary (Mediator)

3Manufacturing precision

If manual insertion is used to ensure precision, then manufacturing precision is improved, but productivity deteriorates due to labor-intensive process

Engineering Contradiction:

Improveinsertion accuracyVSAvoidinsertion speed

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The system performs preliminary straightening of the diptube using a roller mechanism before the insertion operation. The roller applies controlled pressure to the bent tube section, pre-correcting its alignment so that when the sprayer pump is inserted, the tube naturally follows the correct path into the bottle opening, thereby maintaining both speed and precision

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

A guide rod or alignment fixture acts as an intermediary element between the sprayer pump assembly and the bottle opening. This intermediary component provides a physical pathway that forces the diptube into proper alignment during insertion, compensating for bends in the tube while maintaining automated high-speed operation

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS7845148B2Method and apparatus for insertion of uniquely shaped packaging elements

Publication Date: 2010.12.07 PSR AUTOMATION INC

AI summary

In some embodiments, a method of insertion of uniquely shaped packaging elements may include one or more of the following steps: (a) transporting a container along a conveyor, (b) securing the container, (c) aligning a spray cap mechanism over a container opening with a transfer rake assembly, (d) grasping a diptube with a diptube assembly, (e) lowering the diptube assembly and the transfer rake assembly to insert the diptube into the container, (f) securing the container with a timing screw, (g) loading the spray cap mechanism into a sprayer magazine, (h) locking a retractable stop onto the spray cap mechanism, (i) transferring the spray cap mechanism from the sprayer magazine to the transfer rake, (j) locking a second spray cap mechanism with the retractable stop, and (k) retracting the diptube assembly after inserting the diptube into the container.