Electronic Counter for Ultrasonic Sealing Cycle Tracking
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Solution Overview
Problem
The operation of ultrasonic sealing devices in packaging machines is difficult to monitor directly and reliably, leading to potential warranty issues due to the lack of efficient tracking of sealing cycles, especially when components are used across different machines.
Innovation Solution
An electronic counter is integrated with the ultrasonic transducer to count ultrasonic sealing cycles, comprising input terminals, a balanced capacitive voltage divider, a voltage bridge rectifier, a stabilized power supply, a voltage meter, and a microprocessor-based counter, allowing for continuous monitoring of sealing operations and production cycles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If ultrasonic sealing devices are used to seal packaging tubes, then sealing speed and productivity are improved, but reliable monitoring of sealing cycles becomes difficult
Solution Approach 1:
An electronic counter device is introduced as an intermediary between the ultrasonic sealing device and the monitoring system. This counter receives electrical signals from the ultrasonic generator and automatically counts sealing cycles, converting the difficult-to-monitor mechanical sealing process into easily trackable electrical counting data without affecting the high-speed sealing operation
Solution Approach 2:
The patent replaces manual or mechanical monitoring methods with an electronic counting system that uses electrical signals from the ultrasonic generator to automatically track sealing cycles. This substitution of mechanical monitoring with electronic detection enables reliable measurement while maintaining high productivity
2Adaptability or versatility
If ultrasonic sealing devices are transferred between different packaging machines, then equipment versatility is improved, but accurate tracking of sealing cycles for warranty purposes becomes unreliable
Solution Approach 1:
The electronic counter creates a reliable copy or record of the sealing cycle data in non-volatile memory, preserving an accurate history of sealing operations even when the ultrasonic device is moved between different packaging machines. This digital copying of operational data ensures warranty tracking remains precise despite equipment versatility
Solution Approach 2:
The counter device is designed with universal functionality to work with different ultrasonic sealing devices across multiple packaging machines while maintaining accurate sealing cycle counts. The device can serve multiple purposes: counting sealing cycles, storing data in non-volatile memory, and providing reliable tracking regardless of which specific machine or ultrasonic device is being used
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 enables direct, reliable, and efficient monitoring of ultrasonic sealing device operations, facilitating fair warranty claims and settlements by accurately tracking the number of sealing cycles and production cycles.
Implementation Method 1
a balanced capacitive voltage divider (13) connected to said input terminals (11.1, 11.2)
Implementation Method 2
a voltage bridge rectifier (14) connected to said balanced capacitive voltage divider (13)
Data Source
AI summary
Packaging Machine operable to produce sealed packages made of heat-seal sheet packaging material and containing a food product, and comprising an ultrasonic sealing device including an electrical power signal source operable to generate an electrical power signal; an ultrasonic transducer electrically coupled to the electrical power signal source to receive the electrical power signal and responsively heat seal the sheet packaging material; and an electronic counter operable to count the ultrasonic sealing cycles of the ultrasonic sealing device.