Anomaly Detection for Injection Molded Opening Devices on Packaging Web
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Solution Overview
Problem
There is a need for a reliable quality assessment method to ensure that injection molded opening devices on packaging material meet quality requirements and maintain package integrity, as existing techniques lack effective anomaly detection and control mechanisms.
Innovation Solution
A method using a light source and image capturing device setup to illuminate and capture image data of the opening devices from opposite sides of the web, allowing for the detection of anomalies such as holes, cracks, and material deviations, and communicating notification signals for quality control, with optional features including dual light sources, data storage, and machine learning analysis.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If injection molding is used to produce opening devices on packaging web, then production efficiency and integration are improved, but quality assessment and anomaly detection become more difficult
Solution Approach 1:
The patent implements preliminary quality assessment by placing the light source and image capturing device immediately after the injection molding station. This allows anomalies to be detected in real-time during production, enabling immediate corrective action before defective opening devices proceed further in the packaging process, thus resolving the contradiction between high-speed production and quality monitoring
Solution Approach 2:
The patent replaces traditional mechanical inspection methods with an optical detection system using light sources and image capturing devices. This substitution enables non-contact, high-speed anomaly detection that can keep pace with injection molding production rates while providing detailed visual inspection of opening device quality
2Force
If web penetration during molding is implemented, then opening force is reduced and tearing control is improved, but package integrity may be compromised
Solution Approach 1:
The patent employs feedback control by using the image capturing device to detect anomalies in the web penetration process and the opening device structure. This information is fed back to the injection molding system, allowing real-time adjustment of molding parameters to ensure proper penetration depth and web integrity, thus achieving both reduced opening force and maintained package reliability
Solution Approach 2:
The patent utilizes light transmission properties (analogous to color changes) by illuminating the web and opening device with light and capturing the transmitted or reflected light patterns. Different regions of the opening device and web show different light transmission characteristics that indicate proper formation and penetration, enabling visual verification that package integrity is maintained while achieving the desired opening force characteristics
3Reliability
If comprehensive quality assessment is implemented, then package integrity is ensured, but system complexity increases
Solution Approach 1:
The patent extracts only the critical quality parameters for inspection by using a light source and image capturing device focused specifically on detecting anomalies in the opening device and web penetration areas. This selective approach provides comprehensive assessment of package integrity without requiring complex multi-parameter measurement systems, thus maintaining reliability while limiting system complexity
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
This method provides efficient and reliable anomaly detection, enabling real-time quality control, improving package integrity, reducing waste, and optimizing packaging system performance by identifying and addressing issues before packaging is completed.
Implementation Method 1
a light source (308) arranged to emit light passing through the web (302)
Implementation Method 2
an image capturing device (306) arranged to capture the light passing through the web and the opening device
Data Source
Figure 1
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AI summary
A method (100) for detecting anomalies in an opening device (304) on a web (302) of packaging material is disclosed. The opening device (304) is injection molded onto the web in an injection molding station (312). The method (100) comprises: illuminating (S102), by a light source (308), a first side (310a) of the web (302) of packaging material, at a position of the opening device (304); capturing (S104), by an image data capturing device (306), image data depicting the opening device (304) from a second side (310b) of the web (302), the second side (310b) being opposite from the first side (310a); identifying (S106), in the image data, data indicative of an anomaly; and communicating (S114), in response to the anomaly being identified, a notification signal comprising information indicative of the anomaly to a quality control station (316).