An automated method for evaluating candle burning performance

Abstract

This invention discloses a method for automatically measuring, monitoring, and recording candle combustion performance using a vision system. The method includes periodically measuring the candle flame height and acquiring image sequences using a camera. Each candle and its corresponding wick are equipped with a unique identification barcode for recording and storing candle data in a database, along with a date and timestamp. The system issues an audible and visual alarm when the flame height is below half an inch or above two or three inches. Furthermore, the system records all extinguished candles and wicks (including those in the middle and / or late stages of their lifespan). Candle temperature is measured every two hours (the specific frequency depends on the combustion type and cycle), including the temperature of the molten wax pool (an alert is issued when the temperature reaches or exceeds 250 degrees Celsius) and the temperature of the container sidewalls. During the middle and late stages of the candle's lifespan, the system takes photographs of the candle and tracks the fixed position of the wick to monitor wick migration.

Description

Technical Field

[0001] This invention relates to the field of candle combustion performance, and more particularly to an automated method for measuring, monitoring and recording candle combustion performance. Background Technology

[0002] Candle making can be viewed as both a science and an art form. Generally, filled candles are made by cooling wax to a liquefied state. This wax can be paraffin wax, soy wax, beeswax, or similar materials. After the wax liquefies, fragrances and colorants can be added to give the candle its visual appeal and emit a chosen scent. Then, one or more wicks are fixed in a mold: the wick of a single-wick candle is placed in the center, while for multi-wick candles, the wicks are arranged according to the design requirements; the liquefied wax is then poured into the mold. After the wax cools and solidifies, the finished candle is created, which can then be removed from the mold and placed in a candlestick for use.

[0003] Although the making and use of candles seem simple, they actually involve a complex process. The chemical reaction of a candle involves using wax as fuel, vaporizing it through a flame to continuously produce light, heat, and fragrance. During operation, lighting the wick creates a cluster of flames that heats a small amount of wax around the wick. The wick acts as a capillary, causing the molten wax to flow upwards along the exposed wick, drawing the wax into the wick; subsequently, the flame converts the wax into vapor. This vapor combines with oxygen in the air to form a gas. When the oxygen and vaporized wax are fully mixed, the resulting vapor is ignited by the flame at the tip of the wick. This combustion process continues as long as wax can be drawn out through the wick and fuel is continuously supplied. The wax is a hydrocarbon that reacts with oxygen in the flame to produce water and carbon dioxide, releasing energy in the form of heat and light. The carbon particles released during combustion form the visible flame. The bright part of the flame is the area where combustion is taking place; the darker, outer part of the flame is the glow emitted by incompletely burned carbon particles.

[0004] The length of a candle wick is adjusted to control the flame height. A longer wick draws in more wax, providing more fuel for the flame and resulting in a higher flame. If the wick is too long, it can produce a large, flickering flame, which can overheat the candle holder and cause other problems such as wick curling, leading to double wicks or double flames. Conversely, a shorter wick draws in less wax. If the wick is too short, the flame will be small, and the burning efficiency will be reduced.

[0005] Candles are a fuel source, and most countries require manufacturers to conduct quality inspections to ensure they meet specific safety standards. These inspections may include visual inspections, fragrance testing, and, most importantly, combustion testing. By conducting combustion tests, candle manufacturers can optimize formulations and wick selections to produce candles that burn efficiently, look appealing, and meet safety standards. For example, random sampling is a quality control technique that involves selecting a subset of candles from a large batch for inspection and testing. Its core principle is that every candle in the population has an equal chance of being selected. This helps ensure that the selected candles are representative of the entire population and reduces bias in the selection process. When using statistical methods for quality control, random sampling allows us to apply statistical tests and calculations with greater confidence, especially since candle combustion testing is conducted at multiple stages, such as the development stage, pre-screening stage, and post-production combustion testing stage. Results obtained from a sample can be more reliably generalized to the entire population. The larger the sample size, the higher the accuracy of the statistical analysis. However, the more candles tested, the more human resources are required.

[0006] Candles need to be tested to ensure they are safe for use by the general public. To this end, the industry has established corresponding standards that manufacturers must adhere to. For example, in the United States, there are ASTM (American Society for Testing and Materials) standards to ensure the safety, quality, and performance of candles.

[0007] ASTM F2058: Standard test method for measuring the luminance of a fluorescent light source, used to measure the luminance of a candle and determine the luminous intensity of a fluorescent candle.

[0008] ASTM F2326: Standard Test Method for Shipboard Use provides a method for testing candles with a primary focus on their safety and stability on a ship.

[0009] ASTM F2417: Standard Test Method for Fire Safety Assessment of Candles, used to assess the fire safety performance of candles, including their flame retardancy and flame spread characteristics.

[0010] ASTM F2601: Standard test method for determining the amount of residue remaining in a liquid removed from a burning candle.

[0011] ASTM F2399: Test Method for Heat Resistance of Candlesticks, is a standard used to evaluate the heat resistance of candlesticks to ensure that they can withstand the heat generated by burning candles without melting or deforming.

[0012] ASTM F2418, "Guide to Standard Information on Fire Safety for Candles," provides information on candle fire safety, labeling, and user instructions to reduce the risk of fire associated with candles.

[0013] ASTM F2419: Standard test method for determining heat of combustion, used to determine the energy output and burning time of a candle.

[0014] ASTM F2600: Standard Test Method for the Performance of Candle Flame Carbon Deposits, used to determine the amount of carbon deposits produced during candle burning. Excessive carbon deposits are undesirable for both safety and aesthetic reasons.

[0015] Although random sampling and manual testing of candles is standard practice in the industry, the large amount of manual labor required often limits the number of samples that can be taken, making it difficult for the test results to fully represent the characteristics of the entire batch of products. Testing may include: manually observing the candle's burning condition to assess the following indicators: flame size and stability (an ideal flame is typically stable, does not flicker violently, and is of moderate size); wax consumption rate (observing the rate at which the candle consumes wax provides insight into its burning time and overall efficiency); flame height (manually measuring the flame height with a standard steel ruler only provides a rough estimate of the maximum flame height); melt pool temperature (using a handheld temperature probe provides accurate information about the temperature of the molten wax pool); soot (the presence of soot may indicate that the wick is too long, causing the wax to rise along the wick without complete combustion); dripping (the presence of dripping may indicate that the type of wax used is inappropriate and / or that it contains additives); and the molten pool (observing the state of the wax pool around the wick during burning to determine if the molten pool extends to the edge of the candle container or is uniformly formed).

[0016] What the industry lacks is an automated method for evaluating candle combustion performance that can eliminate the various variables that currently affect the accuracy of traditional manual measurements of flame height and molten pool temperature. Summary of the Invention

[0017] A method for measuring, monitoring, and recording candle combustion performance using a vision system and automation technology. In one embodiment, the method includes using a timing element to trigger a camera to capture images, thereby measuring the candle flame height and recording trends in flame height changes. The method employs an automated database to assign a unique identification barcode to each candle and its batch, while simultaneously recording corresponding wick and candle data, along with date and timestamps. Furthermore, the system provides audible and visual alarms, issuing alarms when the flame height is below half an inch or above 2 inches and 3 inches (for higher flame heights, a warning alarm is issued at 2 inches and a termination alarm is triggered at 3 inches). The method can also record all extinguished candles or wicks (including wicks in the middle and late stages of their lifespan). Simultaneously, the candle temperature, the molten wax pool temperature, and the container sidewall temperature are measured, and an alert is issued when the molten wax pool temperature reaches or exceeds a specific threshold of 250 degrees Celsius. Candle images are captured during use and at the end of the candle's lifespan to record flame height and stabilizer position, thereby tracking and determining combustion performance and any wick migration.

[0018] A customized shelving system was further disclosed, with one implementation employing an integrated track for a vision system mounted on the end effector of a six-axis collaborative robot (cobot). Another implementation utilizes a single-track vision system for measuring candle burning performance. The current layout preferably uses a three-tiered shelf, three candles wide, with a total length of 50 feet, and a track on one side of each shelf for movement along the X-axis. The system is equipped with inverter control (soft start and soft stop) to minimize interference from airflow during measurement. Additionally, the device is designed for vertical movement along the Y-axis, allowing the robot's end effector to easily reach each shelf level. Flame image acquisition utilizes a high-resolution camera with appropriate filters. The collaborative robot system has a parking / return position at the end of the shelf for stopping between readings. The human-machine interface is provided via a wall-mounted display and a touch-enabled iPad.

[0019] One object of the present invention is to provide an automated guided vision system for laboratory applications of candle combustion, so as to achieve a unified result of automated measurement, monitoring and recording of combustion performance data.

[0020] Another objective of this invention is to provide an automated testing system capable of accurately and precisely measuring the burning performance of candles, a feat that cannot be achieved using traditional methods such as handheld scales and probes.

[0021] Another objective of this invention is to reduce physical labor in hazardous environments and improve work efficiency.

[0022] However, another object of the present invention is to use camera imaging technology to accurately measure the height of a candle flame, which is traditionally determined manually using a measuring ruler or measuring rod.

[0023] Another object of the present invention is to provide an automated testing system and method that can measure the flame height of a candle at a controlled frequency, determine the temperature of the molten pool and sidewalls, verify compliance with ASTM and abuse testing standards, and record relevant information, readings and images into a database.

[0024] One advantage of the disclosed testing apparatus and method is that it improves worker safety by removing workers from the currently performed manual open flame analysis.

[0025] Another advantage of the testing device disclosed herein is that safety is further enhanced during automatic measurement because it can detect and issue audible and visual alarms to indicate when parameters such as altitude and temperature exceed the specified range.

[0026] The testing apparatus and system disclosed herein also have the advantage of enabling objective testing of candles, thereby allowing for a larger test sample size to improve the reliability of statistical test results.

[0027] Other objects and advantages of the present invention will become apparent from the following description and accompanying drawings, in which several embodiments of the invention are specifically illustrated by way of example. Any drawings contained herein form part of this specification and are exemplary. Embodiments of the invention are described, and their various objects and features are illustrated. Attached Figure Description

[0028] Figure 1 This is a front view of the vision system device;

[0029] Figure 2 It is a perspective view of the vision system device;

[0030] Figure 3 It is a perspective view of the scanning and weighing station;

[0031] Figure 4 The diagram shows cross-sectional views of two tables, each with three shelves.

[0032] Figure 5 yes Figure 4 The table shown is a top view, with two rows of tables in the burn room;

[0033] Figure 6 The image shows a vision system device installed at the end of a collaborative robot arm;

[0034] Figure 7Images at the end of its lifespan are shown, capturing the drift of the wick holder;

[0035] Figure 8 It is a diagram depicting a reading guide; and

[0036] Figure 9 This is a flowchart of an automated method for evaluating the burning performance of a candle. Detailed Implementation

[0037] This document discloses in detail specific embodiments of the applicant's invention. However, it should be understood that the disclosed embodiments are merely exemplary implementations of the invention, which can be implemented in various forms. Therefore, the specific functional and structural details disclosed herein should not be construed as limiting, but rather serve as the basis for the claims and to provide a basis for those skilled in the art to flexibly apply the applicant's invention in virtually any appropriately refined structure.

[0038] Automated methods for evaluating candle burning performance can be based on a small number of candles, but for proper results, statistical analysis of a set of candles is necessary. In one embodiment, a three-tiered shelf structure is used. In this embodiment, the first tier is 8 inches from the ground, and the other tiers are spaced 22 inches apart: from the first tier to the second tier, and from the second tier to the third tier. These shelves employ an open grid structure, ensuring that the candles are spaced approximately 8 inches apart in both directions between the walls. In a preferred embodiment, wooden blocks are used to place the candles on the grid structure; the blocks are preferably 5.5 inches x 5.5 inches in size and 0.5 inches thick.

[0039] In a standard testing room, candles are arranged in layers, ideally with 3 candles placed horizontally and 50 candles arranged vertically on each layer.

[0040] The human-machine interface (HMI) uses a computer program to display the combustion chamber shelf layout and includes a selection menu for the automated system to measure candles. In one implementation, the automated system is based on the movement of a measuring device that can move in the XYZ planes, enabling precise positioning of the measuring device. This movement can be achieved via guide rails or, more commonly, robotic motion. In a preferred embodiment, the robot is a collaborative robot, or "cobot." Such robots are specifically designed and positioned to work collaboratively with humans in a shared workspace. Collaborative robots incorporate sensors and safety features, enabling them to work safely in the presence of a human operator. Regardless of the approach, robotic devices position a vision inspection system on each candle to perform a range of tasks, from simple repetitive tasks to more complex operations, with high accuracy, precision, and repeatability. The device also stores relevant data and images for later reference, evaluation, and analysis. Because collaborative robots are designed to work alongside human workers, they can replace candles as needed, bypassing human workers to perform tasks and further improving efficiency and productivity. Safety is a top priority for collaborative robots, which are typically equipped with force limiting technology and sensors that allow them to automatically stop or slow down when someone enters their work area. Other safety measures include area scanners, driving indicator lights, and audible and visual alarms.

[0041] The measurement procedure includes selecting either the ASTM or ABUSIVE combustion test. For example, for the ASTM combustion test, the following cycle can be set: First cycle: Read data for half an hour, then record the 2-hour and 4-hour markers; subsequent cycles only record the 2-hour and 4-hour markers. For the ABUSIVE combustion test, each cycle only records the 4-hour and 8-hour markers. Alarm prompts: An alarm is triggered when the flame height is less than half an inch or greater than 2 or 3 inches; an SE (Self-Extinguishing) alarm is triggered when the flame is self-extinguishing; a flashover alarm is triggered when flashover occurs.

[0042] In a preferred embodiment, the candle is measured every 2 hours, and a warning is issued when the flame height is below half an inch or above 2 or 3 inches. A warning is also issued when the flame self-extinguishes; an alarm is triggered in the event of a flashover. The warnings can be provided by an audible and visual alarm device.

[0043] Further testing includes flame height measurement, image snapshots (or long-exposure averaging in other implementations); acquiring temperature data for the sidewalls of each candle using an infrared (IR) temperature sensor; for three-wick candles, measuring the melt pool temperature by immersing a K-type thermometer in the center of the wick; for single-wick candles, immersing the thermometer between the wick and the sidewall to a depth accurate to half an inch, with cleaning cycles to prevent cross-contamination between different candles. The system will issue an audible and visual alarm when the melt pool temperature reaches or exceeds 250 degrees Celsius.

[0044] The system captures an image of the candle as it burns out, taken from the top of the candle. The position of the support and the superimposed rings indicate the permissible tolerance for support offset is ±1 / 8 inch.

[0045] In a preferred embodiment, a vision system placed at the end of a robotic arm is used to measure, monitor, and record the burning performance of a candle. The measurement functions included in this vision system are currently performed manually. Each automation method enables faster and more accurate testing. For example, traditionally, the measurement of candle flame height relies entirely on manual operation: operators use metal rulers to measure the flame. This method is not only affected by human factors but also has low accuracy due to unavoidable hand tremors, and poses serious safety hazards due to proximity to the flame. The same applies to the measurement of the molten pool temperature, and the advantages of this invention address these problems. This automated system uses a vision system and automation technology, employing cameras, image processing software, and machine learning algorithms to simulate human vision, achieving the detection, guidance, and automated operation of the candle. This basic automated system includes the following steps:

[0046] Measure the height of the candle flame every 2 hours (the exact frequency depends on the type and cycle of burning), and take 5 photos of each wick (even on a three-wick candle).

[0047] Provide audio and video alarms for the following: any flame alarm less than half an inch; any flame alarm greater than 2 inches and less than 3 inches; and any extinguished candle / wick (in moderate and / or at the end of its life).

[0048] Candle temperature data is acquired every 2 hours (the specific frequency depends on the type and cycle of combustion); the temperature of the molten wax pool is acquired; and the temperature of the container sidewall is acquired.

[0049] Take top and top views of each candle at the end of its lifespan to determine the support position for wick migration.

[0050] The robot is housed within a custom-designed shelving unit, which incorporates an integrated track for the vision system and is mounted at the end effector of a six-axis collaborative robot (cobot). The shelving unit is preferably three stories high, approximately three candlesticks wide, and about 50 feet long (approximately). A track on one side allows the robot to move along the X-axis between each shelf level. Additionally, the unit is designed with vertical movement along the Y-axis to ensure unobstructed access for the robot's end effector to each shelf level.

[0051] The robot employs inverter control (soft start and soft stop) to minimize airflow during the measurement stroke. Flame readings are acquired using a high-resolution camera equipped with a suitable filter. The collaborative robot system has a parking / return position at the end of the shelf for use between readings.

[0052] HMI (Human-Machine Interface): The main HMI screen provides a complete layout of the combustion laboratory. The sub-screens display detailed data on candle batch entry and measurements of candle flame height and temperature, including information before and after combustion.

[0053] In a preferred embodiment, the test is conducted in a combustion test laboratory or combustion chamber, where the temperature is maintained within a constant range of 68 to 85 degrees Fahrenheit (20 to 29.5 degrees Celsius). A constant airflow of less than 35 cubic feet per minute should be maintained at candle level, and the room must have a minimum air exchange rate of 6 times per hour.

[0054] Please now refer to the attached diagram, especially Figure 1 and Figure 2 The diagram illustrates a vision system device 10 for measuring, monitoring, and recording the burning performance of a candle. The device 10 includes a vision housing 12 made of a flame-retardant material, such as flame-retardant carbon fiber. The housing 12 houses a camera 14, designed and arranged to continuously capture a series of images. The camera 14 is equipped with autofocus and a filter suitable for flame detection. In a preferred embodiment, multiple lights 16 are arranged around the camera 14 to achieve optimal image enhancement. The images from the camera 14 are then post-processed by a microprocessor and memory connected to the camera 14. The flame height can be easily calculated using pixels mapped onto a gradient virtual scale. Furthermore, the measurement of distance, measurement angle, and candle height (using a separate ultrasonic sensor in this embodiment) all play a crucial role in ensuring the accuracy of the flame height readings and calculations.

[0055] In a preferred embodiment, the candle flame height is measured every 2 hours (the specific frequency depends on the type and cycle of combustion), and each measurement includes taking 25 photographs of each wick. The measurement data is recorded in a computer database in the form of a predefined template.

[0056] In addition, the vision system device 10 is equipped with an infrared temperature sensor 18 for measuring the temperature of the candle sidewalls; it also includes a thermocouple 20, which is fixed inside the housing 12 and connected via a rotary joint 22. The thermocouple 20 is used to measure the temperature of the candle's molten pool. Depending on the burning type and burning cycle, the temperature of the candle's molten pool and the temperature of the candle sidewalls are measured and recorded every 2 hours. The vision system device 10 is positioned by a collaborative robotic arm and physically moved during the inspection process to precisely place the camera 14 onto each candle to be tested. This movement is controlled by a programmable robot 50, which can move the vision system device 10 along the X, Y, and Z axes to accurately position it on each candle to be tested.

[0057] like Figure 3 As shown, the candles to be tested are placed on the scanning and weighing station 25. Each candle is placed on a weighing sensor 26 with a mounting plate 28, then weighed, and the data is further recorded in the computer system. To track each candle individually, a unique barcode with a serial number is affixed to the side of each candle. While the candle is still on the weighing sensor 26, its unique barcode is read using a barcode scanner 30, and then the barcode is mapped to various data in the computer system.

[0058] Figure 4 A cross-section of the shelf frame 32 is shown, used to space the candles to be measured apart. In one embodiment, a cantilevered three-tier shelf is used, with the first tier 34 8 inches above the ground, and the other tiers arranged sequentially at 22-inch intervals: the second tier 36 is 22 inches above the first tier, and the third tier 38 is 22 inches above the second tier, with each tier supported by a number of uprights 40. The shelf frame 32 is designed to facilitate the movement of the robot 50 along pre-defined X, Y, and Z axes and to accurately measure each candle on the frame 32. In a preferred embodiment, the candles are spaced 8 inches apart between the side walls of the container.

[0059] The first shelf 34, the second shelf 36, and the third shelf 38 all feature ideal welded steel frames with laser-cut sheet metal panels that have undergone powder coating. These shelves are further CNC-machined to achieve a smooth surface finish and employ an open grid design to promote better airflow. These cut holes are designed not only as automatically positioned fixtures to support the wooden bases holding the candles for combustion testing but also as motion coordinate markers for collaborative robots. Proper airflow ensures even candle burning, preventing heat and smoke buildup and thus avoiding biased test results. Furthermore, the reasonable spacing effectively maintains and creates a safe and stable environment, providing excellent ventilation.

[0060] Figure 5 A series of shelving frames 32 in a combustion testing laboratory configuration is shown. In one embodiment, two rows of shelves are parallel to each other, with a track 42 between them. A robot 50 is placed and integrated onto this track 42. The track 42 allows the robot 50 to move along each row of shelves in the X and Y axes. In a preferred embodiment, the robot 50 has a "stop" or "return" position at the end of the track 42. The robot's specific positioning can also be manually controlled by an operator, pre-programmed to achieve repetitive movements along the shelving system, or integrated with machine learning technology so that the robot 50 can automatically identify its position on the track 42. Although the robot's movement is limited to the X and Y axes, the robot 50 can still tilt appropriately if necessary to ensure accurate measurement of the candle's combustion characteristics. For example, these shelves are arranged adjacent to each other, with multiple rows of shelves having a longitudinal measurement length of approximately 50 feet, and the entire workspace being 65 feet. In this way, multiple rows of shelves can be replicated, allowing the robot 50 to work on any row of shelves while sliding on the track 42; at the same time, this layout design can be flexibly adjusted according to the configuration of the actual room or laboratory.

[0061] Please see now Figure 6 A vision system device 10 is placed at the end of a robotic arm. In a preferred embodiment, the robot 50 is a collaborative robot, or "cobot," constructed and positioned to work alongside humans in a shared workspace. Cobots are equipped with sensors and safety features that enable them to interact safely in environments where human operators are present. In either case, the robot-like device positions the vision inspection system 10 onto each candle to perform a range of tasks, including simple repetitive tasks as well as more complex operations. Figure 6A robot 50 is shown manipulating a vision system device 10, located at the end of a robotic arm, surrounding a series of candles placed within a shelf frame 32. In a preferred embodiment, the robot 50 is equipped with a robotic arm for moving the vision system device 10, thermocouples 20, and similar measuring devices.

[0062] Once the batch of candles has been weighed and scanned, and the system has recorded the relevant data, technicians will receive a prompt on the HMI screen asking them to select "Get Candle Positions." The system automatically selects the candle placement positions based on the type of combustion test to achieve optimal candle distribution balance, while also considering the robot's workload, balanced heat output, and minimizing movement distance for maximum efficiency. The HMI screen indicates the candle's specific location by displaying a "flashing green" indicator at the designated placement position. After the candles are placed and lit, technicians must select "All Candles Lighted" on the HMI screen to confirm that the batch has been successfully lit. Subsequently, the location of each candle on the main screen will display a "stable green," indicating that the candle is in a continuous "burning cycle."

[0063] At preset, appropriate reading time points, the robotic arm 52 moves along the X and Y axes, positioning the vision system device 10 to the appropriate location for each candle. Before each reading, the vision system mounted on the end effector of the robotic arm scans the candle's barcode to further confirm the correct candle location; simultaneously, the vision system also captures an image of the candle from above, precisely determining its position on the wooden block. Combustion chamber technicians can input or view real-time data, including status information, appearance inspection results, and pre- and post-combustion data, via a human-machine interface screen. The robot 50 can move the device 10 to the appropriate position: the infrared temperature sensor 18 measures the sidewall temperature, while the thermocouple 20 measures the molten pool temperature via the rotating connector 22. Furthermore, the high-resolution vision system device 10, equipped with autofocus and filters, captures the flame in a continuous image sequence, deriving a maximum value and / or a combined reading of the maximum and average values. When the flame condition exceeds a preset threshold, the system will issue an alarm via audio or visual indicators, indicating self-extinguishing flame, excessively high flame temperature, flashover, or excessively high molten pool temperature. The human-machine interface screen will display these alarm messages in a flashing red light at the corresponding candlestick position.

[0064] Once a candle reaches the end of its designated burning cycle (based on the start time triggered upon entry), the HMI screen displays the candle's location as a flashing blue light to indicate that the candle is about to be extinguished and enters the "extinguishing cycle." Once all candles are extinguished and the technician confirms by selecting "All candles extinguished" on the HMI screen, the main candle interface will display a steady blue light at each candle's location, indicating that the candle is in a continuous "extinguishing cycle" state.

[0065] Please see now Figure 7 Camera 14, equipped with a suitable filter, captures images of the three wicks towards the end of the candle's lifespan to detect any changes in the position of the wick support 44, if any. If the detected movement exceeds a specified range (e.g., 10 mm), the position ring of the support 44 turns red and an alarm is triggered, allowing combustion chamber technicians to identify the issue. The system typically incorporates a ±1 / 8-inch tolerance for detecting migration of the support 44.

[0066] Figure 8 Examples of some combustion test parameters are shown. These tests are based on ASTM or ABUSIVE standards, and the relevant parameters are set and programmed to run automatically. For example, for the ASTM combustion test, the following cycle can be set: First cycle: read for half an hour, then record at 2 hours and 4 hours respectively; subsequent cycles record only at 2 hours and 4 hours. Similarly, for the ABUSIVE test, it is 4 hours. And only at the 8-hour mark, for each cycle. Alarms and thresholds can also be set to alert the cauterization chamber technician if any parameter exceeds the set range. For example, if the flame length is less than ½ inch, the cauterization chamber technician will be alerted to a low flame.

[0067] refer to Figure 9 The image shows an automatic candle testing system 100 for measuring, monitoring, and recording candle burning performance. The steps include:

[0068] Received a batch of 102 candles;

[0069] Visually inspect each candle to ensure it is free of cracks, blemishes, foreign objects, and other defects. 104;

[0070] Scan the barcode attached to each candle, which contains predefined candle data and the corresponding wick, to identify each candle; at the same time, automatically record the candle weight 110 measured by a calibrated weighing sensor connected to the computer system 106.

[0071] A computer system with a display is configured to receive predefined data for each candle and automatically populate this predefined data into a template. As is industry practice, each candle is weighed before and after its burning cycle. In a preferred embodiment, a weighing sensor is used to compare the weight data before and after burning, and this data is input into the computer system.

[0072] The system retrieves the optimal candle position, places the candle in place, and lights it to initiate the burning cycle, while simultaneously confirming the location on the HMI screen 112. In a preferred embodiment, the candle is placed on a 5½-inch square, ½-inch thick wooden block for candle burning testing.

[0073] The vision system device is coupled to a placement mechanism movable along the X, Y, and Z axes, which receives instructions from a computer. The system sequentially and methodically accesses each candle. This placement mechanism is further defined as a robot whose robotic arm can move along the X, Y, and Z axes 142 on a shelf. In a preferred embodiment, the robot is a collaborative robot.

[0074] The vision system is directed to capture a continuous image sequence 116 of the candle flame, and the maximum flame height 118 measured in the image sequence is calculated by a computer system. Subsequently, based on pixel values ​​mapped onto a virtual scale, camera distance, candle height, and tilt angle 120, the actual length and average height of the maximum flame are recorded. In a preferred embodiment, the process of measuring, monitoring, and recording candle combustion performance includes capturing a series of images 138, where the exposure time for each set of images is within a few milliseconds. More specifically, an image sequence of at least 10 images is used to measure the flame height. A preferred image sequence contains 25 images.

[0075] These steps further include a placement mechanism and a vision system located above the end of the candle's burning end, for acquiring top-down images to record the position of the booster at the end of the burning process and displaying the booster's migration trajectory and distance traveled in the top-down image 140;

[0076] These steps also include displaying a flashing red light on the screen when a specific candlestick location requires attention, including high flame / flashover 126 / SE, auto-extinguishing 128, or end-of-life. In a preferred embodiment, both visual and audible alarms are issued simultaneously to notify combustion chamber technicians of safety-related malfunctions. Attention is required when the flame height is below half an inch, or above two or three inches, or when a flashover or auto-extinguishing flame is present. For example, visual alarm 130 and audible alarm 132 will issue alert signals. If the flame height is less than 1 / 2 inch, the combustion chamber technician will be notified; if the flame height is greater than 2 or 3 inches, visual alarm 134 and audible alarm 136 will notify the combustion chamber technician.

[0077] These steps also include using a vision system to measure the candle flame height every 2 hours (the exact frequency depends on the type and cycle of burning), and taking at least 10 images for each candle / wick. The measurement data is then recorded in a computer database using a preset template.

[0078] Connect a thermocouple to measure the temperature of the candle molten pool, and record the molten pool temperature via computer system 122;

[0079] These steps also include: thermocouple detection of the center of the molten wax pool in 2 or 3 wick candles, and thermocouple detection of the molten wax pool between the wick and the side wall of a single wick candle.

[0080] The system includes audio-visual alarm prompts when the molten pool temperature reaches and / or exceeds 250 degrees Celsius;

[0081] The sidewall temperature of a candle is measured using a red (infrared) sensor and recorded by a computer system 124.

[0082] In one embodiment, the steps further include: displaying a first color signal via a computer system when the candle is ready to be tested; displaying a second color signal via a computer system when the candle is ready to be extinguished; and the computer system indicating the start and end of the burning cycle through the flashing and stable state of the corresponding colors.

[0083] Repeat the above steps according to the template until each candle in the batch has been measured, monitored, and its performance in each pre-set burning cycle has been recorded.

[0084] These steps also include adjusting the room temperature used for testing to approximately 68 to 85 degrees Fahrenheit (20 to 29.5 degrees Celsius), maintaining a constant airflow of less than 35 cubic feet per minute at the candle level, and stipulating that there be at least 6 air exchanges per hour in the room.

[0085] The term "coupling" is defined as a connection, but does not necessarily refer to a direct connection or a mechanical connection. In the claims and / or specification, when "a" or "an" is used with the term "comprising," it may mean "one," but also includes "one or more" or "at least one." The term "about" typically refers to plus or minus 5% of the listed value. The word "or" as used in the claims generally means "and / or," unless explicitly stated to be used only to indicate mutually exclusive alternatives, or that these alternatives are mutually exclusive; however, this disclosure supports a definition that refers only to alternatives and includes "and / or."

[0086] The terms “comprising” (and any of its forms, such as “including” and “comprising…”), “having” (and any of its forms, such as “having” and “having…”), “including” (and any of its forms, such as “including” and “including…”), and “containing” (and any of its forms, such as “containing” and “containing…”) are all open-ended connecting verbs. Therefore, a method or apparatus that “comprising,” “having,” “including,” or “containing” one or more steps or elements indicates that it possesses those one or more steps or elements, but is not limited to possessing only those one or more elements. Similarly, a step of a method or an element of an apparatus that “comprising,” “having,” “including,” or “containing” one or more features indicates that it possesses those one or more features, but is not limited to possessing only those one or more features. Furthermore, an apparatus or structure configured as… is configured in a manner that is at least in that manner, but may also be configured in a manner not listed.

[0087] Those skilled in the art will recognize that the present invention is well-suited to achieving the stated objectives and obtaining the mentioned advantages and benefits. The embodiments, methods, procedures, and techniques described herein represent preferred embodiments and are intended to be illustrative rather than limiting the scope of the invention. Various variations and other uses will be discovered in practice by those skilled in the art, all of which are encompassed within the spirit of the invention and defined by the scope of the appended claims. Although the invention has been described in conjunction with specific preferred embodiments, it should be understood that the claims of the invention should not be unduly limited to such specific embodiments. In fact, various modifications to the described embodiments that are obvious to those skilled in the art should be considered to fall within the scope of the following claims.

Claims

1. An automated method for evaluating candle performance, comprising the following steps: a. Received a batch of candles; b. Visually inspect each candle to check for defects such as cracks, blemishes, and debris; c. Scan the barcode attached to each candle, which contains predefined candle data and the corresponding wick, to identify each candle; d. Configure a computer system with a monitor to receive predefined candle data for each candle and automatically populate the template with this predefined candle data; e. Weigh each candle using a weighing sensor to compare the weight data before and after burning, and transmit the weight data to the computer system; f. Using the placement coordinates of the computer system, automatically fill in and record the position of each candle on the shelf; g. During each candle reading within the burning cycle, the wax layer height of each candle is measured according to predefined candle data on the computer system; h. The vision system device is coupled to a mounting mechanism that can move along the XY and Z axes, the mounting mechanism receiving instructions from the computer system to systematically access each of the candles; i. Instruct the vision system to capture a series of images of candle flames, and use the vision and computer system to calculate the maximum flame height measured from these images; at the same time, based on pixels mapped on a progressive virtual scale, record the actual length and average height of the maximum flame, as well as the distance, tilt angle and wax layer height; j. Connect a thermocouple to measure the temperature of the molten wax pool in the candle, and record the temperature of the molten pool using the computer system; k. Use an infrared (IR) sensor to determine the temperature of the candle sidewall and record the sidewall temperature using the computer system; 1. Repeat step 1b until the performance of each candle in the batch is measured, monitored and recorded according to the template.

2. The automated method for evaluating candle performance according to claim 1, wherein the step of weighing the candle is performed by a calibrated force sensor connected to the computer.

3. The automated method for evaluating candle performance according to claim 1, wherein the candle is placed on a 5½-inch square block of wood with a thickness of ½ inch for a candle burning test.

4. The automated method for evaluating candle performance according to claim 1, wherein when attention is required, a flashing red light is displayed on the screen, including low flame and / or high flame / flashover / SE, self-extinguishing, or end of life.

5. The automated method for evaluating candle performance according to claim 4, including audio and video alarms for safety-related faults.

6. The automated method for evaluating candle performance according to claim 1, wherein each frame in the image sequence is within a few milliseconds.

7. The automated method for evaluating candle performance according to claim 1, wherein a sequential sequence of at least 10 images is used to determine the flame height by means of pixels, distance, and measurement angle.

8. The automated method for evaluating candle performance according to claim 1, wherein the thermocouple is used to detect the temperature of the molten pool at the center of the wax pool in a multi-core candle.

9. The automated method for evaluating candle performance according to claim 1, wherein the thermocouple is used to detect the temperature of the molten wax pool located between the wick and the sidewall of the candle in a single-wick candle.

10. The automated method for evaluating candle performance according to claim 5, wherein, If the vision system detects a flame height of less than half an inch or greater than 2 or 3 inches, or if a flashover occurs, or if the flame extinguishes itself, cautionary measures should be taken.

11. The automated method for evaluating candle performance according to claim 1, wherein the placement mechanism and the vision system are positioned at the end of the candle burnout phase to obtain a top-down image, thereby recording the position of the support at the end of the burning process and displaying the migration trajectory and distance of the support in the top-down image.

12. The automated method for evaluating candle performance according to claim 1, wherein the vision system measures the flame height at a frequency of 2 hours based on the burning type and burning cycle, taking a sequence of 25 images at each candle / wick each time.

13. The automated method for evaluating candle performance according to claim 1, comprising the following audiovisual alarms: any flame height less than half an inch; any flame height greater than two inches; any flame height greater than three inches; and any candle / wick that has extinguished at the end of its lifespan.

14. The automated method for evaluating candle performance according to claim 1, wherein the placement mechanism is further defined as a robotic arm movable on the shelf along the X, Y and Z axes.

15. The automated method for evaluating candle performance according to claim 13, wherein the robot is a collaborative robot.

16. The automated method for evaluating candle performance according to claim 1, wherein each candle is placed on a 5½-inch square block of wood with a thickness of ½ inch for candle burning tests.

17. The automated method for evaluating candle performance according to claim 1, comprising the following steps: When the candle is ready to be tested, the computer system displays a first color signal; when the candle is ready to be extinguished, the computer system displays a second color signal; the computer system indicates the start and end of the burning cycle through the flashing and stable state of the corresponding colors.

18. The automated method for evaluating candle performance according to claim 1, comprising the steps of: adjusting the room temperature for testing to approximately 68 to 85 degrees Fahrenheit (20 to 29.5 degrees Celsius) and maintaining a constant airflow of less than 35 cubic feet per minute at the location of the candle; while specifying that the air exchange frequency in the room is at least 6 times per hour.

19. A vision system device for measuring, monitoring, and recording the burning performance of a candle, comprising: A visual shell constructed using flame-retardant materials; A camera built into the housing, the camera being constructed and arranged to capture a series of images; Multiple lights are arranged around the camera to enhance the image effect; A microprocessor and memory connected to the camera calculate the flame height from the image using pixels mapped onto a gradient virtual scale; in this embodiment, the distance, measurement angle, and candle height measurements (using a separate ultrasonic sensor) all play a crucial role in obtaining accurate flame height readings and calculation results. An infrared temperature sensor is used to measure the temperature of the candle's sidewalls; A thermocouple fixed to the outer casing, connected via a rotary joint, is used to measure the temperature of the candle's molten pool; as well as A robot with an end effector for receiving the vision shell; The robot is programmable to move the vision system along the X, Y, and Z axes to reach the position of each candle to be tested.

20. The vision system apparatus according to claim 19, wherein, In this embodiment, the candle flame height is measured every 2 hours, and each measurement includes taking 25 images of each candle / wick.

21. The vision system device of claim 19, wherein the candle melt pool temperature and the candle sidewall temperature are measured and recorded every 2 hours (the specific interval depends on the combustion type and cycle).

22. The vision system apparatus of claim 19, wherein the measurement data is recorded in a computer database using a predefined template.

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