Tissue Packaging Layer Detection and Rejection System
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Solution Overview
Problem
Existing packaging machines for tissue products face inefficiencies due to manual intervention required for correcting errors in product positioning, dimensions, and orientation, leading to machine stoppages, increased costs, and reduced productivity.
Innovation Solution
A machine with a dosing element and loop conveyor system, equipped with detection devices and a processing and control unit, allows for automatic detection and removal of non-conforming layers without stopping the machine, ensuring precise and reliable layer formation and packaging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual intervention is used to correct errors in product positioning, dimensions, and orientation, then the machine can handle non-conforming products, but the machine must stop and productivity decreases
Solution Approach 1:
The system automatically detects non-conforming layers through detection devices and triggers rejection mechanisms without requiring manual intervention. The machine self-corrects by eliminating defective layers while maintaining continuous operation, thus preserving productivity while ensuring quality control
Solution Approach 2:
Detection devices continuously monitor layer conformity and provide real-time feedback to the control system. When non-conforming layers are detected, the system immediately activates rejection mechanisms, creating a closed-loop control system that maintains both quality and continuous production
2Manufacturing precision
If the machine stops for manual correction of errors, then accurate error correction can be performed, but time is lost and costs increase
Solution Approach 1:
The detection devices identify non-conforming layers before they cause downstream problems. The system prepares for rejection by activating mechanisms in advance, allowing continuous operation while maintaining precise quality control without time-loss stoppages
Solution Approach 2:
Manual mechanical correction is replaced with automated detection and rejection systems. Optical sensors, cameras, or other detection devices automatically identify defects and trigger mechanical rejection mechanisms, eliminating the need for manual intervention and maintaining both precision and continuity
3Measurement precision
If detection devices are added to monitor products in channels, then error identification precision improves, but device complexity increases
Solution Approach 1:
The detection devices are integrated into the existing machine structure and serve multiple functions: monitoring product presence, detecting orientation, measuring dimensions, and triggering rejection. This multi-functionality reduces the need for separate specialized devices, managing complexity while maintaining high detection precision
Solution Approach 2:
Multiple detection functions are combined into integrated detection devices that simultaneously monitor multiple parameters (position, orientation, dimensions). The control system consolidates these detection signals and coordinates rejection actions, reducing overall system complexity while improving measurement precision
4Productivity
If automatic rejection of non-conforming layers is implemented, then productivity is maintained, but the system becomes more complex
Solution Approach 1:
The rejection mechanism extracts only the non-conforming layers from the continuous product stream. By isolating and removing only the defective portions rather than stopping the entire system, the machine maintains continuous operation and high productivity with a relatively simple rejection mechanism
Data Source
AI summary
A machine for packaging groups of tissue products includes a dosing element with a plurality of passageways, each for receiving a row formed by a predetermined number of products for defining a layer of a group of products. A detection device associated with the dosing element detects a filling parameter relative to a number, dimension and/or orientation of the products occupying the passageways and generates a signal representing the filling parameter. A processing and control unit receives the signals representing the products and processes the signals to compare with signals relating to a reference layer for deriving an acceptance condition, wherein the layer is consistent with the reference layer and suitable for the packaging, or for eliminating the layer of products released from the dosing element. A rejection system ejects the layer when it is in the eliminating condition.