Adaptive Optical Fill Level Indicator for Packaging Machines
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Solution Overview
Problem
Operators of packaging machines face challenges in determining the fill level of supply units during the packaging process, leading to inefficient operations and potential damage to materials due to reliance on experience and lack of real-time information, resulting in increased work and quality issues.
Innovation Solution
A packaging machine equipped with a display device that uses optical markings adaptable to process parameters such as output rate, packing density, and batch size to indicate the fill level of supply units, allowing operators to quickly and accurately assess the level of packaging materials or goods without relying on experience.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the operator refills the storage unit during the packaging process, then the supply unit is kept filled, but the operator cannot see the display on the man-machine interface and loses access to process parameters
Solution Approach 1:
The patent extracts the essential information (fill level indication) from the complex display system and presents it in a simplified, dedicated visual form on the storage unit itself. The display device on the storage unit shows only the fill level through optical markings, separating this specific information need from the main control interface and allowing operators to quickly assess supply levels without accessing the full MMI.
2Ease of operation
If the operator relies on experience to estimate the fill level, then no additional display devices are needed, but incorrect estimates lead to unnecessary emptying and refilling operations
Solution Approach 1:
The patent implements a feedback system where the display device continuously provides visual information about the fill level through optical markings. This real-time feedback replaces subjective operator estimation with objective visual data, enabling operators to make informed decisions about when to refill, thereby avoiding unnecessary emptying and refilling operations that reduce productivity.
Solution Approach 2:
The patent uses optical markings that can change appearance (such as color or illumination state) to indicate different fill level conditions. This visual differentiation makes it immediately apparent to the operator whether the storage unit is full, partially filled, or empty, eliminating the need for experience-based estimation and enabling quick, accurate assessment of supply levels.
3Reliability
If the supply unit is emptied and refilled repeatedly, then the operator maintains awareness of fill levels, but this causes damage to packaging materials or package goods and reduces machine reliability
Solution Approach 1:
The display device provides continuous visual feedback about the fill level, enabling operators to monitor supply levels without physically accessing or manipulating the storage unit. This eliminates the need for repeated emptying and refilling operations that could damage packaging materials or goods, while maintaining full operator awareness of the fill status through the optical markings.
4Productivity
If a simple fill level indicator is provided, then the operator can quickly assess supply levels, but the indicator cannot adapt to different process parameters such as batch size or output rate
Solution Approach 1:
The patent implements a dynamic display system where the optical markings can be adapted based on process parameters such as batch size, output rate, or optimal operating points. The control unit receives information about these parameters and adjusts the fill level indications accordingly, allowing the same display device to provide context-appropriate information for different packaging scenarios while maintaining quick visual assessment capability.
Data Source
AI summary
The packaging machine comprises a supply unit for holding and providing a plurality of package goods or packaging materials. A display device assigned to the supply unit is configured to display at least one optical marking, which is indicative of a fill level of the supply unit and is different from an alphanumeric display. The at least one optical marking is variably adaptable as a result of at least one process parameter different from the fill level in a way that an assignment of the at least one optical marking to a certain degree of the fill level of the supply unit is changeable. A control unit, which communicates with the display device, is configured to adapt the at least one optical marking as a function of the at least one process parameter different from the fill level.