Track-Routed Container and Closure Delivery for Flexible Filling
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Solution Overview
Problem
High speed container filling systems are inflexible and costly, requiring significant changes to accommodate different container types and fluids, leading to increased downtimes and manual handling inefficiencies, which limits their ability to provide diverse product lines efficiently.
Innovation Solution
A track system with a control system that allows for the simultaneous routing of different container types and fluids, using a network of tracks and vehicles that can be independently routed to various unit operation stations for filling, capping, and decoration, enabling on-demand fulfillment without manual packing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a high speed container filling system is configured to fill one type of container with one type of fluid, then filling efficiency is improved, but adaptability deteriorates requiring significant changes to accommodate different container types and fluids
Solution Approach 1:
The system employs multiple interchangeable nozzle assemblies that can be quickly swapped to accommodate different container types and fluid products. The carrier system is designed with adjustable configurations to handle various container sizes and shapes, allowing a single filling system to perform multiple functions without requiring complete reconfiguration.
Solution Approach 2:
The system incorporates adjustable and reconfigurable components including variable nozzle positions, adjustable carrier configurations, and programmable control systems that can dynamically adapt to different filling requirements. This allows the system to maintain high-speed operation while transitioning between different product types.
2Adaptability or versatility
If the configuration of the system is changed to accommodate different container types and fluids, then adaptability is improved, but downtime increases and productivity deteriorates
Solution Approach 1:
Multiple nozzle assemblies are pre-configured for different container types and fluid products, allowing operators to quickly swap between pre-prepared configurations rather than reconfiguring components during product changes. This preliminary preparation of multiple ready-to-use nozzle sets significantly reduces changeover time.
Solution Approach 2:
The system uses programmable control systems that store configuration data for different product types. When changing products, the control system can recall and automatically adjust parameters based on stored configurations, eliminating manual reconfiguration time and maintaining productivity during transitions.
3Adaptability or versatility
If multiple high speed container systems are employed to provide diverse product line, then product variety is improved, but cost and space requirements increase
Solution Approach 1:
A single filling system is designed to handle multiple container types, sizes, and fluid products through interchangeable nozzle assemblies and adjustable carrier configurations. This eliminates the need for multiple separate filling lines, reducing both capital equipment costs and facility space requirements while maintaining diverse product line capabilities.
Solution Approach 2:
The system combines multiple filling capabilities into one integrated platform by merging different nozzle types, carrier configurations, and control functions into a unified system that can be reconfigured for different products, thereby consolidating what would traditionally require separate systems.
4Adaptability or versatility
If manual handling is used to provide different containers and arrangements in packages, then packaging flexibility is improved, but labor cost and accuracy deteriorate
Solution Approach 1:
The system incorporates automated container handling and positioning mechanisms that self-adjust to create different packaging arrangements based on programmed instructions. The carriers and positioning systems automatically configure containers into required package layouts without manual intervention, maintaining flexibility while eliminating labor-intensive operations.
Solution Approach 2:
The packaging system uses programmable and adjustable mechanisms that can dynamically reconfigure container arrangements according to different packaging requirements. This automated flexibility replaces manual handling while maintaining the ability to accommodate various package designs and configurations.
Data Source
Figure 1
Figure 1A~1B
Figure 1C~1D
AI summary
A method and a system for independently routing vehicles and delivering containers and closures to a unit operation station, said system comprising: at least one container (38) for holding a fluent material, said container having an opening (40); a closure (42) for selectively sealing the opening of a container; a track system (20); a plurality of unit operation stations (84, 86, 88, 90) disposed along the track system, one of the unit operation stations (86) being configured for applying a closure onto a container; a plurality of vehicles (24) propellable along the track system, wherein: each container is disposed on a respective vehicle; and the plurality of vehicles are independently routable along the track system to deliver at least one container and at least one closure to the at least one unit operation station for applying a closure onto a container.