Washing Unit Conveyor Speed Control for Empty Article Positioning

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Solution Overview

Problem

Existing washing units for empty articles face issues with articles falling or accumulating inside conveyor channels, leading to operational disruptions and reduced throughput due to the need for frequent shutdowns and incomplete channels.

Innovation Solution

A feeding system with a sequencing device and sensors that detect and correct the positioning of articles, using levers and actuators to ensure proper alignment and prevent articles from entering the washing tunnel, and a control unit to adjust the chain conveyor speed based on the number of non-operational channels.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If articles are conveyed through channels in the feeding system, then articles can be transported to the inlet station, but articles may fall or accumulate inside the channels causing operational disruptions

Engineering Contradiction:

Improvethroughput of washing unitVSAvoidoperational continuity of washing unit

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The sensor detects articles incorrectly positioned in channels before they enter the washing tunnel, and the sequencing device prevents them from proceeding. This preliminary detection and prevention action avoids operational disruptions downstream, maintaining both throughput and reliability by addressing issues before they cause shutdowns

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The sequencing device acts as an intermediary between the feeding system and the washing tunnel. It receives signals from sensors about incorrectly positioned articles and intercepts these articles before they enter the washing tunnel, preventing potential operational disruptions while maintaining continuous operation of the washing unit

Inventive Principle:

Principle #24Intermediary (Mediator)

2Productivity

If the chain conveyor operates at high speed to maintain throughput, then productivity increases, but the risk of articles falling or being incorrectly positioned increases

Engineering Contradiction:

Improvethroughput of washing unitVSAvoidpositioning accuracy of articles

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

Sensors positioned along the channels provide real-time feedback about article positioning to the control system. This feedback enables the sequencing device to identify and correct positioning errors before articles enter the washing tunnel, allowing the chain conveyor to operate at optimal speed while maintaining positioning accuracy through continuous monitoring and correction

Inventive Principle:

Principle #23Feedback

3Reliability

If shutdowns are performed to remove fallen articles or undesired objects, then operational reliability is maintained, but productivity is significantly reduced

Engineering Contradiction:

Improveproper operation of washing tunnelVSAvoidthroughput of washing unit

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

Sensors detect articles or undesired objects incorrectly positioned in channels before they can cause operational problems in the washing tunnel. The sequencing device prevents these detected items from entering the washing tunnel, eliminating the need for shutdowns and maintaining continuous high-speed operation

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The sequencing device serves as an intermediary barrier that intercepts incorrectly positioned articles or undesired objects detected by sensors. By preventing these items from reaching the washing tunnel, the system maintains proper operation without requiring shutdowns, thus preserving productivity while ensuring reliability

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentEP3401028B1A washing unit for treating empty articles

Publication Date: 2022.10.19 GEBO PACKAGING SOLUTIONS ITAL

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AI summary

There is disclosed a washing unit (1) for treating empty articles (2), comprising: a plurality of feeding channels (104) for advancing respective rows (101) formed each of a respective plurality of empty articles (2); and a chain conveyor (4) with seats (17) and cyclically movable between an inlet station (I) at which it is fed, in use, by feeding channels (104) with respective sequences (21) of one or more empty articles (2) to be washed and an outlet station (0) at which it discharges, in use, washed empty articles (2); a sensing group (30) for sensing the number of seats (17) which do not receive articles (2); and a control unit (114) operatively connected with sensing group (30) and chain conveyor (4) and programmed for adjusting the speed of chain conveyor (4) on the basis of number (N), so as to keep constant the throughput of washing unit (1).