Transfer Element for Tubular Bag Machine Asynchronous Filling
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Solution Overview
Problem
High-performance tubular bag machines face challenges in maintaining synchronicity between the dosing device and the filling device, leading to standstills or idle cycles, which limits performance increases due to complex synchronization requirements.
Innovation Solution
A transfer element with an input station, dispensing station, and transfer containers, controlled by a transfer control system that allows for asynchronous transfer by adjusting the seal position and speed, enabling early initiation of the transfer process before complete stoppage, and utilizing transfer containers with expanding cross-sections for efficient filling material flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If synchronous operation between dosing device and tubular bag machine is maintained, then filling precision is ensured, but machine performance is limited due to standstills and idle cycles
Solution Approach 1:
The system is divided into independent modules: dosing device, transfer element with multiple transfer containers, and filling device. Each transfer container operates independently, allowing the dosing device to fill containers asynchronously while the filling device receives material without requiring complete system synchronization, thus eliminating standstills while maintaining filling precision.
Solution Approach 2:
The dosing device prepares filling material in advance by filling transfer containers before they are needed at the filling position. This preliminary action allows the filling device to receive pre-prepared material without waiting for real-time dosing, eliminating idle cycles and improving overall machine performance while maintaining precise filling control.
2Manufacturing precision
If transfer containers come to complete standstill before dispensing, then precise positioning is achieved, but process time increases reducing packaging performance
Solution Approach 1:
The transfer container is positioned at the dispensing location before complete stoppage occurs. The sealing operation is initiated in advance while the container is still moving, allowing the transfer process to begin before the container comes to a complete standstill. This reduces process time while maintaining sufficient positioning precision for accurate filling.
Solution Approach 2:
The system transitions from static positioning (complete standstill required) to dynamic positioning (positioning during motion). The transfer container moves at controlled speed while the sealing and transfer operations are dynamically adjusted to match the container's position and speed, eliminating the need for complete stoppage and reducing process time.
3Productivity
If high-speed transfer of filling material is implemented, then packaging performance increases, but synchronization complexity increases making maintenance difficult
Solution Approach 1:
The high-speed transfer system is segmented into independent transfer containers that operate autonomously. Each container is filled and dispensed independently, eliminating the need for complex multi-point synchronization. The dosing device and filling device operate at high speed without requiring precise coordination, as the transfer containers buffer and decouple the two operations.
Solution Approach 2:
The transfer containers serve as intermediaries between the dosing device and filling device. They receive material from the dosing device and deliver it to the filling device, decoupling the two operations. This intermediary buffer allows both devices to operate at high speed independently, eliminating complex synchronization requirements while maintaining high packaging performance.
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 increases packaging performance by reducing process time and eliminating the need for complete standstill synchronization, allowing for higher cycle rates and flexible adaptation to different filling materials.
Implementation Method 1
each prespecified filling quantity of a filling material for being filled into a tubular bag is transferred from the dosing device into each transfer container (13) located in the input station (11). Subsequently, the transfer containers (13) are transported to the dispensing station (12) along a transfer line (14)
Data Source
AI summary
A transfer element for being arranged between a dosing device and the filling device of a tubular bag machine, the dosing device allowing for the dosing of a prespecified filling quantity of the filling material to be filled into a tubular bag, and the transfer element comprising at least one input station, at least one dispensing station and several transfer containers, and a prespecified filling quantity of a filling material being transferable from the dosing device to the transfer containers in the input station, and the transfer containers being transported to the dispensing station along a transfer line, and the filling material being transferable from the transfer containers to the filling device in the dispensing station, and the transfer containers being transported back to the input station along a return transfer line, the transfer element being controlled by a transfer control system, the transfer control system controlling the transfer process for transferring the filling material from a transfer container to the filling device of the tubular bag machine in the dispensing station a) in accordance with the position of the transfer container relative to the filling device and/or b) in accordance with the speed of the transfer container.