Tubular Bag Machine Format Change Automation
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Solution Overview
Problem
Tubular bagging machines face challenges in reliably and efficiently handling fluctuating product supplies and frequent format changes, leading to increased downtime and operational complexity due to the need for manual adjustments and disassembly of feed chains and carriers.
Innovation Solution
The implementation of transfer robots, such as picker lines, to manage product supply and adjust feed chain speed, combined with modular and easily interchangeable carrier designs that allow for quick format changes without extensive disassembly, and the use of automated tool magazines to facilitate driver changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the running speed of the supply chain is adjusted to match fluctuating product supply, then productivity is improved, but the sealing temperature must be continuously adjusted which increases device complexity and reduces reliability
Solution Approach 1:
The sealing temperature is pre-adjusted to a higher value before speed changes are made. This preliminary temperature adjustment ensures that when the supply chain speed is increased to handle fluctuating product supply, the sealing process remains reliable without requiring continuous temperature modulation during operation.
Solution Approach 2:
The patent changes the operational parameters by adjusting the sealing temperature to a higher level and maintaining it, while allowing the speed parameter to vary. This parameter substitution approach resolves the contradiction by making the temperature parameter fixed at a higher value rather than continuously adjustable, thereby reducing device complexity while maintaining productivity.
2Adaptability or versatility
If format changes are performed frequently to handle different products, then adaptability is improved, but downtime increases due to manual disassembly and reassembly of feed chains and carriers
Solution Approach 1:
The feed chain system is segmented into modular components including interchangeable carriers and detachable side guides. This segmentation allows individual components to be quickly swapped without disassembling the entire feed chain structure, enabling rapid format changes while minimizing downtime.
Solution Approach 2:
The patent implements dynamic, adjustable side guides that can be quickly repositioned or replaced depending on the product format. This dynamic design allows the machine to adapt to different products without requiring complete reconfiguration, significantly reducing the time lost during format changes while maintaining high adaptability.
3Reliability
If complex accumulation measures are implemented to handle disordered product delivery, then reliability of filling is improved, but device complexity increases due to additional buffer devices
Solution Approach 1:
Products are preliminarily organized and positioned on the supply chain before entering the tubular film formation area. This preliminary arrangement ensures that products are correctly oriented and spaced, eliminating the need for complex buffer devices while maintaining reliable filling operation.
Solution Approach 2:
The supply chain system is designed to automatically organize and position products as they are fed into the machine. The carriers and side guides work together to self-organize the product flow, providing reliable filling without requiring additional complex buffer or accumulation devices.
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 ensures reliable and efficient filling of tubular bags even with varying product supplies and allows for rapid format changes, reducing downtime and operational complexity by automating key processes and simplifying carrier and tool management.
Implementation Method 1
sealing elements via a defined sealing time and with a defined sealing temperature in engagement with the film material
Implementation Method 2
seal the two film layers against one another by means of heat or ultrasound, i.e. fusing and gluing
Implementation Method 3
seal the two film layers against one another by means of heat or ultrasound, i.e. fusing and gluing
Data Source
Figure 1
Figure 2a
Figure 2b
AI summary
To enable fast changeover times and a consistently correctly filled feed chain on a tubular bag machine, the products are transferred from a feeder into the compartments of the feed chain by means of pickers, usually robots. Depending on the product supply, the speed of the feed chain is regulated within a limited range so that the sealing temperature of the subsequent tubular bag sealing tools can be adjusted accordingly. The pickers, or a separate carrier changer, can attach, reposition, or replace the carriers on the feed chain with new, differently designed carriers using interchangeable or permanently attached carrier tools. This automates the format change of the tubular bag machine and enables it to be carried out in an extremely short time.