Article Feeder Orientation Control via Vision Sorting
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Solution Overview
Problem
Article feeding devices, such as cap feeders in bottling lines, often result in improperly oriented articles due to vibration and shaking, leading to reduced throughput as these need to be reprocessed.
Innovation Solution
An article feeding device with an orientation control system that uses a camera to detect the orientation of articles and directs them to either a track that maintains proper orientation or a helical path to invert improperly oriented articles, ensuring all articles are correctly oriented before output.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If vibration and shaking methods are used to move and orient articles in the feeder, then articles are moved through the feeding device, but many articles become improperly oriented and require reprocessing
Solution Approach 1:
The system performs preliminary orientation detection using a camera before articles enter the vibration zone. Based on the detected orientation, the system pre-configures the vibration pattern to correct improper orientations, preventing the need for reprocessing and maintaining high throughput while ensuring proper orientation.
Solution Approach 2:
The system uses camera-based detection to monitor article orientation in real-time and provides feedback to the vibration control system. The vibration parameters are dynamically adjusted based on the detected orientation status, creating a closed-loop control system that maintains high orientation precision while preserving throughput speed.
2Productivity
If conventional vibration feeders are used to process articles, then articles are moved through the device, but a large percentage require reprocessing reducing overall efficiency
Solution Approach 1:
The system performs preliminary orientation detection and classification before articles enter the vibration zone. Articles are pre-sorted into properly oriented and improperly oriented groups, allowing the vibration system to apply targeted correction only where needed, thereby maximizing effective output and minimizing reprocessing time.
Solution Approach 2:
The system dynamically changes vibration parameters (frequency, amplitude, duration) based on the detected orientation status of articles. Properly oriented articles receive minimal or no vibration treatment, while improperly oriented articles receive customized vibration patterns, optimizing processing efficiency and reducing overall reprocessing time.
3Manufacturing precision
If orientation detection and selective routing is implemented, then all articles can be properly oriented, but device complexity increases
Solution Approach 1:
The system replaces complex mechanical orientation sensing and routing mechanisms with a camera-based vision system and software-controlled vibration actuation. The camera captures images for orientation detection, and software algorithms determine the appropriate vibration pattern, eliminating the need for complex mechanical sensors and multi-path routing mechanisms while achieving high orientation accuracy.
Solution Approach 2:
The system introduces a camera-based vision system as an intermediary between the article input and the vibration mechanism. This intermediary provides non-contact orientation detection and enables software-based control of the vibration parameters, simplifying the overall system architecture while maintaining high precision orientation control.
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
The solution achieves 100% throughput of properly oriented articles in a single pass, significantly improving efficiency over conventional methods where a large percentage of articles require reprocessing.
Implementation Method 1
The orientation control system may include a camera configured to provide image data of the articles at the input and the orientation control system may determine whether the articles are in the first orientation or the second orientation by comparing the image data to a stored image
Implementation Method 2
The second orientation portion comprises an input, first and second output paths connected to the input, a servo dial located at the interface between the input and the first and second output paths
Data Source
AI summary
According to the present disclosure, an article feeding device that reliably and consistently outputs properly oriented articles includes an input configured to receive articles, an output configured to dispense properly oriented articles, an orientation alteration portion between the input and output, and an orientation control system. The orientation alteration portion includes a first track configured to allow properly oriented articles to pass therethrough without alteration and a second track configured to alter the orientation of improperly oriented articles. The orientation control system is configured to detect orientation of the articles at the input and to send the articles to either the first track or the second track depending upon the detected orientation.