Adaptive Bottle Mouth Lighting for Rust Detection
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Solution Overview
Problem
Existing inspection devices for bottles of different colors struggle to reliably detect rust deposits at the mouth area due to uniform lighting, leading to incorrect sorting and potential product contamination.
Innovation Solution
A lighting unit with adjustable color and intensity, arranged in concentric rings around a center point, emits light that is partially coupled into the bottle mouth, allowing for color-modulated and intensity-controlled illumination, combined with a camera adapted to the light source color space, to enhance rust detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If uniform lighting is used for inspection, then the device complexity is reduced, but the measurement precision deteriorates due to unreliable rust detection on bottles of different colors
Solution Approach 1:
The lighting system transitions from static uniform illumination to dynamic adaptive illumination. The control unit adjusts the spectral composition and intensity of light sources in real-time based on the detected bottle color, enabling the same lighting system to optimally illuminate bottles of different colors (clear, green, brown, blue) for consistent rust detection accuracy across all bottle types
Solution Approach 2:
The lighting system modifies physical parameters (spectral composition and intensity) of illumination based on bottle color characteristics. By changing the wavelength distribution and brightness levels according to the specific bottle color detected, the system achieves reliable contrast enhancement for rust deposits regardless of the bottle's base color
2Measurement precision
If color-modulated lighting is used to improve rust detection, then the measurement precision improves, but the device complexity increases due to multiple light sources and control systems
Solution Approach 1:
The lighting system employs multi-functional LED modules that can emit multiple wavelengths (blue, green, red) and operate in different modes (single wavelength, combined wavelengths, varying intensities). This universal lighting component replaces what would traditionally require multiple separate light sources and control systems for different bottle colors, achieving high measurement precision while managing device complexity through component consolidation
Solution Approach 2:
The control unit receives feedback from the inspection system about bottle color characteristics and automatically adjusts the lighting parameters accordingly. This closed-loop feedback mechanism eliminates the need for manual intervention or complex mechanical switching systems, achieving adaptive color-modulated illumination through automated electronic control that simplifies the overall device architecture
3Measurement precision
If intense lighting is used to enhance visibility of rust deposits, then the measurement precision improves, but the object-generated harmful factors increase due to potential bottle heating
Solution Approach 1:
The lighting system dynamically adjusts intensity parameters based on bottle color and inspection requirements. Rather than using constantly high-intensity lighting, the system applies moderate intensity with optimized spectral composition that provides sufficient contrast for rust detection while minimizing thermal energy transfer to the bottle, thereby avoiding heating-related harmful effects
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 solution enables reliable detection of rust deposits on bottles of various colors, preventing contaminated bottles from entering the production process and ensuring product hygiene.
Implementation Method 1
emitted light is at least partially coupled into the interior of the bottle mouth wall
Implementation Method 2
the lighting unit, i.e., the light source board, is controlled stroboscoposcopically, i.e., flashes, preferably color-modulated and/or intensity-modulated, when a bottle to be inspected is within the inspection area
Data Source
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AI summary
The invention relates to an inspection device (1) for monitoring bottles (2) or similar containers, comprising at least one lighting unit (6) and at least one camera (7), wherein the at least one lighting unit (6) is arranged above the bottle (2) to be examined. In order also to be able to examine bottles (2) of different colours, and in order to be able to detect, for example, also rust deposits (4) reliably, according to the invention the lighting unit (6) is designed as a light source circuit board (6), the light sources (8) of which emit light that can be changed at least in colour to a bottle colour determined in the region of a bottle mouth (3), wherein the light sources (8) are arranged in radially spaced light source rings (9), each concentric about a midpoint of the light source circuit board (6), and emitted light is coupled at least partially into the interior of the bottle mouth. By means of LEDs, light modulated in colour at least to the bottle colour is expediently coupled into the inner wall of the bottle mouth (3).