Three-Head Continuous Packaging and Sealing to Reduce Product Stress
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing packaging machines for small-sized products face challenges in achieving high output while minimizing product stress and noise, handling product tolerances, and reducing complexity, especially in intermittent operation.
Innovation Solution
A method and device utilizing three continuously rotating working heads for packaging and sealing, where each product is assigned packaging material, folded around it on the first head, and sealed on the third head, with processes optimized to reduce stress and accommodate larger tolerances, using a continuous operation principle.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If intermittent operation is used to achieve high output (up to 2,000 products per minute), then productivity is improved, but product stress increases due to impact and collision processes
Solution Approach 1:
The patent applies continuous operation principle where products are conveyed continuously through the packaging process without stopping between operations. The conveyor belt maintains constant motion, and packaging operations (wrapping, sealing, cutting) are performed while products are in motion, eliminating the impact and collision processes inherent in intermittent operation while maintaining high output of up to 2,000 products per minute
2Productivity
If intermittent operation with short cycle times (60 ms) is used, then productivity is improved, but device complexity increases due to high dynamic demands on work components
Solution Approach 1:
The continuous operation system eliminates the need for rapid acceleration and deceleration cycles required in intermittent operation. Work components operate at steady state with constant conveyor speed, eliminating the need for complex dynamic control systems, lightweight construction measures, and sophisticated synchronization mechanisms while achieving the same high output
Solution Approach 2:
The patent transitions from static intermittent operation (with repeated start-stop cycles) to dynamic continuous operation. The system maintains constant motion throughout the packaging process, with packaging operations synchronized to the continuous conveyor flow, thereby reducing dynamic loads on components while maintaining high productivity
3Productivity
If intermittent operation is used to achieve high output, then productivity is improved, but noise level increases requiring complex shielding
Solution Approach 1:
The continuous operation eliminates the repeated start-stop cycles of intermittent operation, which are major sources of noise from motors, drives, and mechanical impacts. The steady-state continuous motion reduces vibration and impact noise, lowering the overall noise level while maintaining high output, thereby reducing or eliminating the need for complex noise shielding
4Productivity
If intermittent operation is used to achieve high output, then productivity is improved, but susceptibility to product tolerances remains problematic with only very limited tolerances processable
Solution Approach 1:
The continuous conveyor operation provides stable, consistent product positioning and spacing throughout the packaging process. The constant motion and uniform conveyor speed create predictable timing and positioning for packaging operations, allowing the system to accommodate larger variations in product dimensions while maintaining high output, thereby processing larger product tolerances compared to intermittent operation
Data Source
Figure 1~2(j)
AI summary
The present invention relates to a method and a device for packaging and sealing small products such as chocolate pieces, bouillon cubes or tablets, hard caramels, soft caramels, washing machine or dishwasher tablets. To ensure the gentlest possible handling of the products while achieving the highest possible packaging performance, the invention aims to achieve a high degree of product-friendliness.To achieve output, the invention discloses a method for packaging and sealing small products on three continuously rotating work heads (3, 4, 5), wherein each product (P) is assigned a packaging material (V) on the first work head (3), wherein each product (P) with its assigned packaging material (V) is then transferred to the second work head (4), on which the product (P) is packaged by folding the assigned packaging material (V) around the product (P), wherein each packaged product (P) is then transferred to the third work head (5), on which the packaging material (V) assigned to each product (P) is sealed. The invention also provides a corresponding device (1).