Overview

This video provides a walkthrough of the main components used at Station 4 for dosing and filling.

Unlike the previous Station 4 procedures, this video focuses primarily on identifying the components, explaining their function, and showing basic inspection, removal, installation, and adjustment points.

Understanding these components makes Station 4 easier to inspect, maintain, and troubleshoot.

Tumbler Proximity Sensor

The dosing section includes a proximity sensor used to detect whether the tumbler is correctly in position.

Before operating or troubleshooting the dosing system, verify that the tumbler is properly installed and that the proximity sensor detects it.

This provides the machine with confirmation that the component is in its expected position.

Product Sensor

The next component is the product sensor, which monitors the product level entering the dosing chute.

Its vertical position can be adjusted using the adjustment knob.

Raising the sensor allows more product to accumulate in the dosing chute before the sensor is triggered.

Lowering the sensor reduces the amount of product allowed into the dosing chute.

This gives the operator a mechanical way to influence how much material is available to the dosing system.

Dosing Vibrator and Gate

The dosing section also contains the vibrator and dosing gate.

The vibrator helps move product through the dosing system, while the dosing gate controls when product is released.

These components work together with the dosing parameters on the HMI to control product delivery.

The dosing chute can also be removed when access is required for cleaning or maintenance.

Cleaning the Removable Dosing Components

The video demonstrates a removable component retained by a latch.

When cleaning is required, release the latch and remove the component.

The technician specifically recommends cleaning this component with alcohol before reinstalling it.

After cleaning, reinstall it and make sure it clips securely back into position.

Scale Assembly

The dosing system includes the scale used to measure the product before it proceeds to filling.

The top portion of the scale assembly is removable.

If it becomes detached, reinstall it carefully and make sure it clicks completely into position and sits straight.

Incorrect installation or positioning of the scale components can interfere with accurate operation.

Moving the Turret Safely

When moving the turret manually, support the cup and keep it straight.

Wait until the appropriate indicator light is active, then lift the turret and cup together before moving the assembly to the side.

This provides access to either side of the dosing assembly.

The cups themselves are removable and can be unclipped when replacement, cleaning, or maintenance is required.

When reinstalling a cup, make sure it is properly secured in its clip.

Reject Gate

Station 4 includes a reject gate for doses that fall outside the acceptable weight range.

If a dose is detected as overweight or underweight, the machine automatically directs that product toward the reject gate instead of continuing with the normal filling process.

The rejected product can then be collected and handled according to the production procedure.

Compaction Needle

The filling section contains the compaction needle.

The needle should be inspected for both straightness and alignment with the cone holder.

To check it, lower the needle close to the cone holder without allowing it to enter completely.

Rotate the needle manually while observing its movement.

Check Needle Centering

In addition to checking whether the needle is straight, verify that it is centered over the opening in the cone holder.

The needle should approach approximately through the center of the opening.

If it is not centered, the Station 4 base provides mechanical adjustment points.

The video shows adjustment bolts that allow the assembly to be moved side to side, along with additional adjustment points used to move the base in or out.

Use these adjustments when alignment correction is required.

Verify the Needle Spring and Washer

Whenever the needle is removed, check the hardware used with the needle assembly.

• A spring below the needle assembly
• A top washer above it

Both components should be present and correctly installed when the needle is reassembled.

Remove the Filling Funnel

The filling funnel can be removed for inspection, cleaning, or replacement.

Release it from its mounting position and use the rear ledge to remove the funnel from the assembly.

The bottom of the funnel contains identification markings.

The video references funnel markings such as 84, 26, or 126.

Always verify the identification on the funnel when confirming that the correct tooling is installed for the product configuration.

Reinstall the Funnel Assembly

The mounting system uses three locating points.

Align the three mounting positions and insert the component correctly into the base.

When installing the retaining clip, make sure the clip sits flat.

The clip and mounting points contain grooves that need to align correctly.

Insert the front points first, then apply slight pressure toward the rear and push the assembly straight into position.

Install the Upper Funnel

The upper funnel uses three magnetic mounting points.

Place the funnel into position and lower it onto the assembly.

A slight rotation can be used to help locate the magnetic mounting points.

You should feel the magnets engage when the funnel is properly seated.

Before operating the machine, verify that the funnel is stable and correctly positioned.

Air Jet Adjustment

Station 4 includes an adjustable air system directed toward the paper.

The adjustment knob controls how much air is blown downward into the paper before it moves upward into the filling position.

The air helps expand/open the paper, allowing it to enter the funnel correctly and helping the detection system read the paper properly.

Adjust the air only as much as necessary to obtain reliable paper positioning.

Filling Funnel Vibrator

A second vibrator is located on the filling funnel.

This vibrator controls how quickly product travels through the filling funnel and into the paper.

Control the Filling Speed

Increasing vibration increases the rate at which product travels into the paper.

However, faster is not always better.

If the product is fed too quickly, material can accumulate and plug the funnel opening.

This can cause poor filling toward the bottom of the pre-roll.

Product may also remain behind in the filling system instead of entering the current paper.

When that remaining product falls during the next cycle, it can contribute to inconsistent finished weights.

The filling vibrator should therefore be adjusted to provide a steady product flow without overwhelming the funnel.