Ultrasonic Blister Pack Separator with 3D Pocket Positioning
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Solution Overview
Problem
Existing separator devices for blister packs are not suitable for complex layouts and require high precision to avoid damaging closely spaced pockets, leading to increased manufacturing and maintenance costs, and are not effective for all types of blister packs, including those with transparent pockets or large text on the base.
Innovation Solution
A separator device equipped with a system for identifying pocket positions relative to the edge of the blister pack using a combination of three-dimensional profiling devices, such as laser line scanners, and photometric stereo systems, which provide precise cutting schemes for various blister pack types, including those with complex layouts, transparent pockets, and large text, ensuring accurate separation without damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional blade separator devices are used for blister packs with complex layouts, then the device structure remains simple, but the device cannot effectively separate pockets with complex arrangements
Solution Approach 1:
The patent replaces traditional mechanical blade-based separation systems with ultrasonic vibration technology. The ultrasonic cutting head uses high-frequency mechanical vibrations to cut through blister pack materials, enabling effective separation of complex layouts without requiring complex mechanical blade arrangements. This substitution of the cutting mechanism allows the device to handle diverse blister pack configurations while maintaining relatively simple device structure.
Solution Approach 2:
The ultrasonic cutting head is designed to be universally applicable to various blister pack types including different layouts, transparent pockets, and packs with large text. By using ultrasonic vibration as the cutting mechanism, a single device configuration can effectively separate multiple types of blister packs that would otherwise require different specialized blade arrangements, thereby achieving multi-functionality without proportionally increasing device complexity.
2Reliability
If high precision cutting is used to avoid nicking closely spaced pockets, then pocket integrity is maintained, but manufacturing and maintenance costs increase due to tight tolerances and constant monitoring
Solution Approach 1:
The patent employs ultrasonic vibration at high frequency to perform the cutting operation. This mechanical vibration approach allows for precise cutting action with a smaller effective cutting edge width compared to traditional blades. The oscillating motion enables the cutting head to navigate closely spaced pockets (less than 2 mm apart) without nicking them, while the system can operate with less stringent mechanical tolerances and requires less frequent monitoring, thereby reducing manufacturing and maintenance costs while maintaining pocket integrity.
3Strength
If traditional blade thickness of 0.65 mm is used, then the blade is structurally sound, but the blade width compromises pocket integrity when pockets are spaced less than 2 mm apart
Solution Approach 1:
The ultrasonic cutting head utilizes high-frequency mechanical vibrations to achieve cutting with an effectively narrower cutting edge. The oscillating motion allows the cutting edge to engage and sever materials with minimal lateral displacement, enabling precise cutting of pockets spaced less than 2 mm apart. This vibrational cutting mechanism maintains the structural strength of the cutting element while achieving the precision necessary for closely spaced pockets, overcoming the limitation of traditional thick blades.
Solution Approach 2:
The cutting system transitions from a static blade to a dynamically oscillating ultrasonic cutting head. This dynamic operation allows the cutting edge to effectively reduce its width during the cutting process through rapid back-and-forth motion, enabling precise separation of closely spaced pockets while maintaining the structural integrity of the cutting element through controlled vibration rather than relying solely on static blade thickness.
4Reliability
If separator devices are designed for specific blister pack types, then the device can achieve reliable separation, but the device cannot handle other blister pack types with different layouts
Solution Approach 1:
The ultrasonic cutting head system is designed with universal applicability to handle various blister pack types including different layouts (linear, grid, complex patterns), transparent pockets, and packs with large text or graphics. The ultrasonic vibration mechanism provides consistent cutting performance across different materials and configurations, allowing a single device design to reliably separate multiple blister pack types that would otherwise require specialized blade arrangements for each specific type.
Solution Approach 2:
By replacing the traditional mechanical blade system with ultrasonic vibration technology, the device achieves greater adaptability to different blister pack configurations. The ultrasonic cutting head can effectively cut through various materials and layouts without requiring complex mechanical adjustments or specialized blade geometries, thereby maintaining separation reliability across diverse pack types while enhancing device versatility.
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
The device enables precise, reliable, and economical separation of blister packs with minimal maintenance, ensuring no damage to medicines and reducing debris and waste, while being adaptable to any blister pack type, including those with challenging configurations.
Implementation Method 1
This separator device uses an ultrasonic cutting head to cut the blister packs along paths predetermined according to cutting schemes
Implementation Method 2
A separator device equipped with a system for identifying pocket positions relative to the edge of the blister pack using a combination of three-dimensional profiling devices, such as laser line scanners
Implementation Method 3
A separator device equipped with a system for identifying pocket positions relative to the edge of the blister pack using a combination of three-dimensional profiling devices, such as laser line scanners, and photometric stereo systems
Data Source
AI summary
Device for separating products grouped in blister packs with a plurality of pockets. The device includes a system for identifying the positions of the pockets relative to the edge of the blister pack. The system for identifying the positions of the pockets relative to the edge of the blister pack includes a three-dimensional profiling device and/or a photometric stereo viewing system.