Automated Sampling Control Station for Bottle Filling Lines
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Solution Overview
Problem
Current sampling control stations for bottles or containers filling plants require manual intervention and specific settings for different container dimensions, are bulky, and do not allow for automated reinsertion of tested containers into the line, limiting their operational efficiency and flexibility.
Innovation Solution
A fully automated sampling control station with a grasping and transporting mechanism that can adapt to various container dimensions by gripping near the annular ribbing at the container's mouth, allowing for centralized positioning on measurement modules and automated reinsertion into the production line, utilizing a mobile support structure with actuators for precise alignment and movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual intervention is used to pick up containers for sampling control, then operational flexibility is maintained, but productivity is reduced and labor costs increase
Solution Approach 1:
The system enables automated self-service through the robotic manipulator that autonomously picks up containers from the conveyor, transports them to measurement modules, and returns them without human intervention. The control unit coordinates the entire process automatically based on container identification data.
Solution Approach 2:
Manual mechanical operations are replaced by an automated robotic system comprising a robotic manipulator with gripper, mobile support structure with actuators, and electronic control unit that processes container data and coordinates movements, eliminating the need for manual container handling.
2Manufacturing precision
If gripping means are set for each container dimension, then positioning precision is improved, but device complexity and operation time increase
Solution Approach 1:
The robotic manipulator serves multiple functions: identifying container dimensions via optical sensor, selecting appropriate gripper settings, executing the pick-up, transporting the container, and positioning it on measurement modules. This single multi-functional device replaces multiple specialized devices that would be needed for each container type.
Solution Approach 2:
The system dynamically adapts to different container dimensions by using optical sensors to read container codes, automatically adjusting gripper parameters and manipulator positioning based on the identified container type, allowing precise handling of various container sizes without manual reconfiguration.
3Measurement precision
If sampling control station is designed for specific container types, then measurement precision is improved, but adaptability to different container dimensions deteriorates
Solution Approach 1:
The system performs preliminary identification of container dimensions and type using optical sensors before the measurement process begins. This advance information allows the control unit to pre-configure the robotic manipulator and select appropriate measurement modules, ensuring both precision and adaptability.
Solution Approach 2:
The system uses feedback from optical sensors that read container codes and dimensions to continuously adjust the robotic manipulator's actions and positioning. This closed-loop control ensures accurate handling and measurement for each container type while maintaining the ability to adapt to new container variations.
4Productivity
If automated pick-up means are provided, then productivity is improved, but device bulk and complexity increase
Solution Approach 1:
The sampling control station is segmented into modular functional units: optical identification system, robotic manipulator with gripper, mobile support structure with measurement modules, and control unit. This modular segmentation allows each component to be optimized independently while reducing overall system complexity through standardized interfaces.
Solution Approach 2:
The system merges the identification, gripping, transport, and measurement functions into a single integrated robotic station. The mobile support structure combines multiple measurement modules that can be positioned by the robotic manipulator, consolidating what would otherwise be separate devices into one compact unit.
5Reliability
If containers are diverted for sampling control, then quality inspection is improved, but line productivity is reduced
Solution Approach 1:
The system implements periodic sampling control by diverting containers at predetermined intervals rather than continuously removing them from the line. This periodic inspection maintains production flow while ensuring adequate quality monitoring, balancing reliability and productivity.
Solution Approach 2:
The robotic manipulator quickly performs the pick-up, transport, and return operations in rapid succession, minimizing the time containers are removed from the production line. The fast automated operations reduce the impact on overall line throughput while maintaining thorough quality inspection.
Data Source
AI summary
The sampling control station comprises at least one grasping and transporting group (22) for picking up containers or bottles (16) from conveying means (18) and transporting them to at least one measuring module (21′,21″,21′″), the containers or bottles (16) being provided with a body tapered into a neck and ending with a mouth, wherein an annular ribbing (19) is foreseen at the mouth, and it is characterized in that the grasping and transporting group (22) comprises gripping means (23) connected to a mobile support structure (30), the gripping means (23) being mobile between a gripping position, in which they are engaged with the neck of the container (16) at and below the annular ribbing (19), and a release position in which they are not engaged with the container (16).