Continuous Strip Cutting and Joining for Defect Removal

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Solution Overview

Problem

Existing automated apparatuses for producing straws struggle with efficiently removing defective products from a continuous strip while maintaining a constant predefined pitch, leading to reduced productivity due to the difficulty and time-consuming nature of detecting and extracting defects, as well as inaccuracies in rejoining the strip.

Innovation Solution

An apparatus with motorized dragging members and sensor systems that detect defective sections, cut them out, and rejoin the strip by moving sections close to restore the predefined pitch, using cutting and joining mechanisms to recreate a continuous strip with consistent spacing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If defective products are detected and extracted from the continuous strip, then product quality is improved, but productivity decreases due to the time-consuming nature of defect removal and strip rejoining

Engineering Contradiction:

Improveproduct qualityVSAvoidproduction speed

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The apparatus performs preliminary positioning of the continuous strip using motorized dragging members before defect detection and removal. The strip is pre-positioned and held in place during the defect extraction process, enabling rapid removal without disrupting the overall production flow. This preliminary preparation allows the system to maintain high productivity while ensuring reliable defect removal.

Inventive Principle:

Principle #10Preliminary action

2Reliability

If the continuous strip is cut to remove defective sections, then defective products are eliminated, but the predefined pitch between products is not accurately maintained after rejoining

Engineering Contradiction:

Improvedefect eliminationVSAvoidpitch accuracy

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The apparatus incorporates sensor means that detect the position of products and the pitch between them in real-time. During the defect removal and strip rejoining process, these sensors provide feedback to the control unit, which automatically adjusts the motorized dragging members to maintain the predefined pitch accuracy. This closed-loop feedback system ensures both effective defect elimination and precise pitch maintenance.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The invention replaces manual or simple mechanical cutting and rejoining methods with an automated system using motorized dragging members and sensor-controlled positioning. This substitution of mechanical systems with automated, sensor-guided mechanisms enables precise control over the cutting and rejoining process, maintaining pitch accuracy while removing defective sections.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Productivity

If the apparatus operates at high speed to maintain productivity, then production output increases, but the complexity of detecting and extracting defects while maintaining pitch increases

Engineering Contradiction:

Improveproduction outputVSAvoiddetection and extraction system complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The motorized dragging members serve multiple functions: they advance the continuous strip during normal operation, position and hold the strip during defect detection, extract defective sections, and rejoin the strip after removal. This multi-functionality reduces the need for separate specialized mechanisms, thereby managing device complexity while maintaining high-speed operation and accurate defect extraction.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 reliable and quick extraction of defective products while maintaining a constant pitch between packaged items, enhancing productivity by automating the process and ensuring consistent strip formation.

Implementation Method 1

sensor means disposed upstream of the first dragging member and configured to detect a defective or faulty section on the continuous strip

Methodology Applied

Scientific EffectOptical detection: Absorption (EM radiation)

Implementation Method 2

cutting means configured to cut the continuous strip in a direction parallel to the separation welds in order to separate the defective section from the continuous strip

Methodology Applied

Scientific EffectMechanical cutting: Fracture Mechanics

Implementation Method 3

joining means configured to join together the free ends of the first section and of the second section, after the first and second sections have been made to meet

Methodology Applied

Scientific EffectWelding: Welding

Data Source

PatentEP4149695B1Apparatus and method for cutting and joining a continuous strip of products packaged in a row

Publication Date: 2023.09.20 IMA IND MASCH AUTOMATICHE SPA

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AI summary

The apparatus for cutting and joining a continuous strip of products packaged in a row comprises a sensor configured to detect a defective section in the continuous strip, cutting means for cutting the defective section, removal means for removing the defective section from the strip and joining means for recreating the continuous strip. The invention also concerns a corresponding method for cutting and joining a continuous strip of packaged products.