Tablet Sorting Pneumatic Acceleration in Rotary Presses
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Solution Overview
Problem
In rotary presses for making tablets, the existing methods for sorting out bad-tablets are unreliable due to congestion and misdirection, which can cause damage to machine parts and disrupt production.
Innovation Solution
The implementation of a system using multiple nozzles to generate air streams that accelerate sorted tablets into separate channels, preventing congestion and misdirection, with individually adjustable air pressures to optimize sorting behavior based on tablet type and production conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a stationary wiper is used to direct tablets into the good-channel, then the conveyance of good-tablets is simplified, but tablets may queue up or congest in the region of the wiper or in the good-channel, altering the position of tablets in front of the ejection nozzle
Solution Approach 1:
The patent introduces a pneumatic system with nozzles that generate air streams to accelerate tablets. The first nozzle generates an air stream to accelerate sorted tablets into the bad-channel, while the second nozzle generates an air stream to accelerate good-tablets into the good-channel. This pneumatic assistance prevents congestion by actively propelling tablets through the channels, ensuring reliable sorting while maintaining smooth conveyance.
2Reliability
If an air blast is generated to eject bad-tablets, then bad-tablets can be directed into the bad-channel, but the air blast must be generated at a precise moment when the bad-tablet is disposed in front of the entry of the bad-channel, requiring precise timing control
Solution Approach 1:
The patent employs preliminary action by using sensors to detect bad-tablets before they reach the ejection point, and by pre-positioning the air stream from the first nozzle to be ready for immediate activation. The control unit is programmed to activate the air stream at the optimal moment based on predicted tablet position and speed, ensuring reliable ejection without requiring complex real-time timing adjustments.
3Productivity
If bad-tablets are blown into the bad-channel with high air pressure, then sorting efficiency is improved, but tablets may hit the wall of the bad-channel and get reflected, thereby getting into the good-channel or impeding successive tablets
Solution Approach 1:
The patent applies local quality by directing the air stream from the first nozzle at a specific angle and position to accelerate tablets into the bad-channel without excessive force that would cause reflection. The air stream is localized to the entry region of the bad-channel, providing just enough acceleration to prevent congestion while avoiding excessive pressure that would cause tablets to hit walls and reflect back into the good-channel.
4Reliability
If the air stream is generated permanently during operation, then congestion in the bad-channel is prevented, but energy consumption increases
Solution Approach 1:
The patent implements periodic action by controlling the air stream from the first nozzle to operate only when needed - specifically when bad-tablets are present and require acceleration into the bad-channel. The control unit activates the air stream periodically based on detection signals rather than continuously, preventing congestion during critical moments while avoiding unnecessary energy consumption during normal operation.
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 enhances the reliability of bad-tablet sorting and prevents congestion in both bad and good channels, ensuring continuous production without negatively affecting the conveyance of good-tablets into the good-channel.
Implementation Method 1
a tablet that has been sorted out is accelerated by means of an air stream directed into the bad-channel
Implementation Method 2
a returning of the tablet to the die plate is avoided
Data Source
AI summary
A method for sorting tablets at a rotary press for making tablets, comprising the following steps: the individual tablets are monitored with regard to at least one property of their condition during the pressing process, and a bad-signal is generated, if a tablet does not fulfill the property, and tablets which do not generate a bad-signal being good-tablets; the good-tablets are directed from a die plate of the rotary press into a good-channel; after a bad-signal has been generated, a bad-tablet is directed into a bad-channel by means of an air blast; by means of a further air stream, which is directed into the bad-channel, the bad-tablet is accelerated into the bad-channel whereby a returning to the die plate is avoided.