Tray Portion Arrangement Feedback for Precise Sealing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing packaging systems face challenges in maintaining the precise shape, size, and position of portions on packaging elements, particularly in troughs, due to factors like centrifugal force and non-constant accelerations, leading to uneven slices and positional errors, which can result in incomplete sealing and aesthetically unappealing arrangements.
Innovation Solution
A method that automatically adjusts production parameters of upstream units, such as knife speed and conveyor belt movements, based on real-time feedback from sensors to ensure that the portion arrangement meets predetermined target values within specified tolerance ranges, ensuring correct placement and sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If portions are produced using high-speed slicing machines with rotating blades, then productivity is improved, but manufacturing precision deteriorates due to centrifugal force and non-constant acceleration causing uneven slice positions and shapes
Solution Approach 1:
A camera system captures images of portions on the conveyor belt to determine their actual arrangement, and this information is fed back to automatically adjust production parameters (knife position, conveyor speed) to correct deviations from target arrangement
Solution Approach 2:
The system dynamically changes production parameters including knife cutting position, conveyor belt speed, and portion spacing based on real-time feedback to maintain precise portion arrangement despite high-speed operation
2Adaptability or versatility
If portions are transported through multiple conveyor belts and buffer zones, then adaptability is improved, but manufacturing precision deteriorates due to further changes in portion size, shape and position
Solution Approach 1:
The camera system monitors portion arrangement after transport through conveyors and buffers, and feedback control adjusts upstream production parameters to compensate for transport-induced deviations
Solution Approach 2:
The system determines the target arrangement in advance and pre-adjusts production parameters to anticipate and compensate for expected deviations during transport through multiple conveyor stages
3Manufacturing precision
If a camera system is used to record portion positions and adjust production parameters, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The system replaces complex mechanical adjustment mechanisms with automated optical detection (camera) and electronic control to adjust production parameters, simplifying the overall control architecture
4Shape
If portions are placed centrally in tray recesses, then aesthetic appearance is improved, but reliability deteriorates if portions lie on sealing edges preventing tight sealing
Solution Approach 1:
The system uses a jet of compressed air to blow portions away from the sealing edge and into the recess, providing a simple and effective mechanism to ensure both aesthetic appearance and sealing reliability
Data Source
Figure 1a
Figure 1b~2b
Figure 2a
AI summary
To ensure that the portions are visually appealing, i.e., centered, with a uniform disc spacing (19) in the longitudinal direction (10*) and also in the transverse direction (11), not differing too much, and in particular not resting on the sealing edge (R) of the trough belt (22) in its trough (M), the corresponding actual arrangement of a portion is determined directly in the packaging machine (100) by means of a camera (26), and if there is too great a deviation from the target arrangement, the production parameters in the upstream portion generation unit (13), in particular the portioning belt (17a) and/or the cutting unit (7) of the slicing machine (1), and/or the portion delivery unit (14) and/or the packaging delivery unit (15) are readjusted, i.e. across the gap between the portioning belt (17a) and the packaging machine (100).