Variable-Speed Rotary Feeder for Uniform Capsule Filling

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Solution Overview

Problem

Existing machines for filling single-use capsules for extraction or infusion beverages face challenges in maintaining uniform product weight, leading to variability and inefficiencies due to complex and costly screw feeder systems prone to clogging and dosing inaccuracies.

Innovation Solution

A filling unit with a rotary element system that rotates at variable speeds based on angular position to ensure uniform product distribution across multiple seats, reducing variability and improving productivity while being simpler and more reliable.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If screw feeder systems are used for filling capsules, then filling capability is achieved, but device complexity increases and reliability decreases

Engineering Contradiction:

Improvefilling capabilityVSAvoidsystem complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The filling system is divided into multiple independent filling stations arranged circumferentially around a central axis, with each station having its own hopper and filling mechanism. This segmentation allows parallel filling operations while keeping each individual station simple and maintainable

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The rotary mechanism serves multiple functions: it positions hoppers, controls filling timing, and enables simultaneous operation of multiple filling stations. This single rotary component replaces what would otherwise require multiple independent feeding mechanisms

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Productivity

If screw feeder systems are used for filling capsules, then filling capability is achieved, but manufacturing cost increases

Engineering Contradiction:

Improvefilling capabilityVSAvoidmanufacturing cost

Core Design Contradiction:

ProductivityVSEase of manufacture

Solution Approach 1:

Multiple filling operations are combined into a single rotary mechanism that positions and operates hoppers sequentially. This merging reduces the total number of components needed compared to having separate screw feeders for each filling position, thereby reducing manufacturing cost

Inventive Principle:

Principle #5Merging (Combining)

3Productivity

If screw feeders are used for product descent, then filling is achieved, but dosing accuracy decreases due to clogging and soiling

Engineering Contradiction:

Improvefilling operationVSAvoiddosing accuracy

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The product descent function is extracted from the screw feeder mechanism and achieved instead through controlled gravity flow from elevated hoppers. This eliminates the screw mechanism that causes clogging and soiling, improving dosing accuracy while maintaining filling capability

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

Product is pre-positioned in hoppers at elevated positions before filling begins. This preliminary positioning allows controlled release and gravity-driven descent into capsules, ensuring consistent dosing without the need for mechanical feeding during the actual filling moment

Inventive Principle:

Principle #10Preliminary action

4Productivity

If multiple independent filling devices are used for parallel rows, then productivity increases, but reliability decreases due to multiple failure points

Engineering Contradiction:

Improvesimultaneous filling of multiple rowsVSAvoidmachine reliability

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

A single rotary mechanism performs the filling function for multiple stations, replacing what would otherwise require multiple independent filling devices. This universal mechanism reduces the number of potential failure points while maintaining the ability to fill multiple capsules simultaneously

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS11548670B2Unit and method for filling containing elements of single-use capsules for extraction or infusion beverages

Publication Date: 2023.01.10 IMA IND MASCH AUTOMATICHE SPA

AI summary

Described is a unit for filling containing elements (2) of single-use capsules (3) with a dose (33) of product for extraction or infusion beverages, comprising: a line (4) for transporting containing elements (2); a station (SR) for filling the containing elements (2) with a dose (33) of product which comprises: at least a first containing seat (S1) designed to receive a dose (33) of product; a substation (ST1) for forming the dose (33) provided with a device (6) for releasing a predetermined quantity of product defining the dose (33) inside the first containing seat (S1), the release device (6) comprising a hopper (38) and at least one rotary element (40a) having a helical profile which extends between a first end and a second end, configured to rotate about a respective axis (X4) of rotation; a drive and control unit (15) configured to drive the rotary element (40a) according to a speed of rotation variable as a function of an angular position of the first end of the rotary unit (40a).