Variable Support Transfer Wheel for Gap-Free Container Production
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing blow molding and filling systems face difficulties in efficiently producing and filling containers of different sizes, as the productivity of the blow molding and filling modules are not easily adjustable to accommodate varying container volumes, leading to gaps in the filling process and challenges in maintaining process-technological parameters.
Innovation Solution
The number of support elements on the transfer wheel is adjusted based on production speed, allowing for the transfer of containers from the blow molding module to the filling module without gaps, by arranging a discharge wheel with support elements in front of the transfer wheel and a feeding wheel with support elements behind it, enabling flexible operation and adaptation to different container sizes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the number of support elements on the transfer wheel is fixed, then the mechanical construction is simple, but the system cannot adapt to different container sizes and production speeds
Solution Approach 1:
The transfer wheel is designed with a variable number of support elements that can be dynamically adjusted based on production requirements. The support elements are arranged such that their quantity can be changed to match different container sizes and production speeds, transforming a static system into a dynamic one that adapts to varying operational conditions.
Solution Approach 2:
The transfer wheel is designed to perform multiple functions by accommodating different numbers of support elements. This universal design allows the same transfer wheel mechanism to handle various container sizes and production rates, eliminating the need for multiple specialized transfer wheels for different production scenarios.
2Productivity
If the productivity of blow molding and filling modules is fixed, then the process parameters are stable, but the system cannot efficiently produce containers of different sizes
Solution Approach 1:
The system enables changes in production parameters by adjusting the number of support elements on the transfer wheel. This parameter adjustment allows the system to optimize productivity for different container volumes while maintaining stable process parameters through controlled synchronization between blow molding and filling modules.
Solution Approach 2:
The system incorporates feedback mechanisms that monitor the synchronization between blow molding and filling operations. By detecting gaps or mismatches in the production rhythm, the system can adjust the number of support elements or operational timing to maintain continuous, gap-free production flow adapted to different container sizes.
3Ease of operation
If gaps occur in the filling process, then the system can handle variable production rates, but the manufacturing efficiency decreases
Solution Approach 1:
The transfer wheel with adjustable support elements ensures continuous transfer of containers from blow molding to filling without gaps. By optimizing the number of support elements to match production rates, the system maintains uninterrupted workflow, eliminating idle time and ensuring continuous useful action throughout the manufacturing process.
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 allows for seamless production and filling of containers of varying sizes without gaps, maintaining process-technological parameters and ensuring continuous operation by adjusting the support elements on the transfer wheel, thereby enhancing the manufacturing and filling efficiency.
Implementation Method 1
the support element is supported by a rotating transfer wheel
Implementation Method 2
the support element is supported by a rotating transfer wheel, and wherein the transfer wheel constitutes at least a portion of a coupling between a blow molding module for the manufacture of containers and a filling module for filling the containers
Data Source
AI summary
The method and the apparatus are used for blow molding and for filling containers. To this end, after a thermal conditioning step, a preform is shaped into a container using blowing pressure inside a blow molding tool. The blow molded containers are positioned at least along part of the transport path thereof by a carrying element, which is held by a rotating transfer wheel. The transfer wheel provides at least part of a coupling between a blow molding module for producing the containers and a filling module for filling the containers. An outfeed wheel of the blow molding module can be arranged in a transport direction of the containers upstream of the transfer wheel, and an infeed wheel of the filling module can be arranged in said transport direction downstream of the transfer wheel, wherein each wheel can be equipped with carrying elements for the containers. The number of carrying elements (42) in the region of the transfer wheel (41) is varied in accordance with a production speed.