Independent Torque-Limited Cap Assembly for Thread Alignment
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Solution Overview
Problem
Existing packaging systems face challenges in automating the application of top closures, particularly for spray bottles, due to issues like bent sprayer pump tubes, inconsistent torque, and difficulty in aligning threaded caps, leading to inefficiencies and potential damage or leakage.
Innovation Solution
A packaging system with independently operated torque limiter assemblies and chuck assemblies, utilizing pneumatic motors, servo motors, and encoders for precise control and alignment of container tops, ensuring proper sealing without damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If automatic capping machines are used to apply top closures, then productivity is improved, but manufacturing precision deteriorates due to inconsistent torque and alignment issues
Solution Approach 1:
The system dynamically adjusts the torque applied during capping operations based on real-time feedback from torque sensors and alignment data from vision systems. The capping machine transitions from fixed mechanical torque to variable, controlled torque application, allowing consistent precision across different container types while maintaining high productivity through automated adaptive control.
Solution Approach 2:
The system incorporates torque sensors, vision systems, and controllers that continuously monitor alignment and torque application during capping. This feedback loop allows the system to detect misalignment or torque deviations and automatically adjust subsequent capping operations, ensuring consistent manufacturing precision while maintaining automated high-speed operation.
2Device complexity
If linear mechanical systems are used for sprayer pump insertion, then device complexity is reduced, but manufacturing precision deteriorates due to inability to handle bent tubes and alignment
Solution Approach 1:
The system replaces simple linear mechanical insertion with a more sophisticated mechanism that includes vision-guided positioning, flexible tube manipulation capabilities, and controlled insertion forces. The system can detect bent tube positions using vision systems and automatically adjust the insertion path, maintaining acceptable device complexity while achieving high positioning accuracy for sprayer pumps.
3Manufacturing precision
If manual labor is used for container top application, then manufacturing precision is improved through careful alignment, but productivity deteriorates due to time-consuming processes
Solution Approach 1:
The system incorporates self-aligning features where the container and container top are automatically positioned using vision guidance and robotic manipulation. The system performs its own alignment function without requiring manual intervention, achieving both high precision and high productivity through automated self-positioning capabilities.
4Reliability
If high torque is applied to secure container tops, then reliability is improved through proper sealing, but object-affected harmful factors increase due to overtightening damage
Solution Approach 1:
The system applies preliminary torque to initially secure the container top, then uses vision systems and torque sensors to detect proper alignment and sealing engagement. Once sealing is confirmed, the system automatically reduces or releases excess torque, preventing overtightening damage. This preliminary action followed by corrective anti-action ensures both seal integrity and container safety.
Solution Approach 2:
The system uses torque sensors and vision systems to continuously monitor the capping process and provide feedback to the controller. When proper sealing engagement is detected, the system automatically adjusts torque levels to prevent overtightening, ensuring reliable sealing while eliminating harmful overtightening effects through real-time feedback control.
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 efficient, accurate, and adaptable application of container tops, reducing risks of overtightening or undertightening, and preventing cross-threading, suitable for various container configurations and types.
Implementation Method 1
The chuck assembly includes a pneumatic motor. Operation of the pneumatic motor causes the chuck assembly to grip or release a container top.
Implementation Method 2
The torque limiter is coupled to the chuck assembly and includes a servo motor and an encoder. Operation of the servo motor causes rotation of the chuck assembly.
Implementation Method 3
The torque limiter is coupled to the chuck assembly and includes a servo motor and an encoder. Operation of the servo motor causes rotation of the chuck assembly.
Implementation Method 4
secure the container top to the container by rotating the chuck assembly using the torque limiter assembly such that torque applied to the container top remains below a torque threshold
Data Source
AI summary
Systems, methods, and apparatus are disclosed herein for assembling a container cap to a container, which utilizes one or more independently operated torque limiter assemblies for securing a container top to a container. A packaging system for assembling a container can include chuck assemblies, torque limiter assemblies, and a controller. The controller can be configured to command each chuck assembly and/or torque limiter assembly independently from other assemblies within the packaging system. Threads of the container top and the corresponding attachment component can be properly orientated and aligned independently of other container tops and corresponding attachment components prior to securing action, such as to preclude each attachment component from being over-tightened or under-tightened relative to the respective container.