Acoustic Emission Sensor for Blow Molded Container Top Load Testing
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Solution Overview
Problem
Current top load testing methods for blow molded containers are either destructive and time-consuming, reducing productivity in inline inspection systems, or not suitable for continuous testing of a flowing stream of containers.
Innovation Solution
A method and device for high-speed, non-destructive top load testing that applies a controlled force to blow molded containers, measuring force and compression, and comparing the linear correlation to stored data to determine compliance with top load performance standards, allowing for inline testing of a continuous flow of containers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If destructive top load deflection testing is performed to ensure container strength, then container strength verification is improved, but productivity is reduced due to time-consuming testing
Solution Approach 1:
The patent replaces the mechanical destructive compression test with an acoustic emission detection system. Sensors detect acoustic signals generated by the container wall under load, allowing non-destructive assessment of structural integrity and strength verification without physical damage or time-consuming procedures.
Solution Approach 2:
The patent introduces acoustic emission signals as an intermediary parameter to assess container strength. Instead of directly measuring physical deformation or damage, the system detects acoustic waves generated by stress in the container wall, providing indirect but reliable strength verification that is both fast and non-destructive.
2Measurement precision
If manual insertion is used in top load testers to ensure accurate testing, then measurement precision is improved, but productivity is reduced due to inability to test continuous flow
Solution Approach 1:
The patent enables the container to perform the testing function itself by detecting acoustic emissions generated during normal handling and stacking operations. The container's own structural response under load provides the test data, eliminating the need for manual insertion or external testing equipment, thereby enabling continuous flow testing without compromising accuracy.
Solution Approach 2:
The patent replaces manual mechanical insertion and positioning with automated acoustic emission detection. The system uses sensors to detect acoustic signals from containers moving through the production line, eliminating manual operations while maintaining measurement precision through objective acoustic signal analysis.
3Reliability
If high vertical force is applied to test top load resistance, then strength verification is improved, but container damage occurs reducing usability
Solution Approach 1:
The patent replaces direct mechanical force application with acoustic emission detection. By monitoring acoustic signals generated during gradual loading, the system verifies top load resistance without applying forces high enough to cause damage, thus maintaining both verification reliability and container integrity.
Solution Approach 2:
The patent applies only the minimum necessary force to generate detectable acoustic signals, rather than applying excessive force to the point of failure. This partial action is sufficient for verification purposes while preserving container integrity and usability.
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
Enables fast, non-destructive top load testing of blow molded containers, improving productivity by distinguishing between acceptable and non-acceptable containers without damaging them, and allowing for real-time quality control in a continuous manufacturing process.
Implementation Method 1
an acoustic emission sensor arranged to detect an acoustic signal generated by the blow molded container
Data Source
AI summary
A method and device for determining the compliance of blow molded containers with respect to a requested top load performance is disclosed. The height of a blow molded containers is determined, and a measuring head is connected to apply an increasing force onto the top of the blow molded container. The compression of the blow molded container is continuously measured along with the force applied. The application of the force is terminated before a non-linear correlation between force and compression is recorded and an accept or non-accept signal is generated by comparison with stored data.