Bottle Seam Detection Lighting Unit for Surface Adaptation
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Solution Overview
Problem
Existing detection systems struggle to accurately identify bottle seams and embossings on containers with varying surface qualities, such as matte or rough surfaces, leading to potential misalignment of labels and poor appearance.
Innovation Solution
A detection system with a lighting unit featuring vertically aligned columns of light sources that can be controlled based on surface properties, projecting a variably adjustable light pattern to enhance the recognition of bottle seams and embossings, using a combination of cameras and a control unit to generate block-like light patterns that are less affected by surface irregularities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a regular stripe pattern is projected onto the container wall, then bottle seams and embossings can be recognized on glossy surfaces, but the pattern becomes blurred and indistinct on matte or rough surfaces, rendering detection inaccurate
Solution Approach 1:
The lighting unit dynamically adapts its operation mode based on detected surface properties. The control unit switches between first operating mode (for glossy surfaces) and second operating mode (for matte/rough surfaces), making the system flexible and adaptive to different container types rather than using a fixed illumination pattern.
Solution Approach 2:
The system changes the illumination parameters based on surface quality detection. For matte or rough surfaces, the lighting unit projects a diffuse light pattern instead of a regular stripe pattern, altering the light distribution parameters to match the scattering characteristics of the surface and enable accurate feature detection.
2Measurement precision
If vertically aligned columns of light sources are used to project stripe patterns, then bottle seams can be detected, but the system cannot accommodate containers with different surface properties that require different light patterns
Solution Approach 1:
The lighting system transitions from a static configuration to a dynamic one where the control unit adjusts the illumination pattern based on real-time surface property detection. The system can switch between different operating modes (first mode for glossy, second mode for matte/rough surfaces), enabling it to adapt to various container types while maintaining detection accuracy.
Solution Approach 2:
The lighting unit is designed to perform multiple functions by accommodating different illumination patterns. It can project both regular stripe patterns (for glossy surfaces) and diffuse light patterns (for matte/rough surfaces), making the system universal and applicable to various container surface properties without requiring separate detection systems.
3Ease of operation
If a fixed light pattern is projected onto the container, then the detection system is simple to operate, but it cannot generate variably adjusted light patterns adapted to different surface properties
Solution Approach 1:
The detection system performs self-adjustment by automatically detecting surface properties and selecting the appropriate illumination pattern without requiring manual intervention. The control unit autonomously switches between operating modes based on the detected surface characteristics, maintaining ease of operation while achieving adaptability.
Solution Approach 2:
The system incorporates feedback from surface property detection to adjust the illumination pattern. The control unit receives information about the container surface and automatically selects the appropriate light pattern (regular stripe or diffuse), creating a closed-loop system that is both simple to operate and highly adaptable.
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
Enables precise detection of bottle seams and embossings regardless of surface quality, ensuring accurate label alignment and avoiding creases or elevations, thus improving the appearance and quality of labeled containers.
Implementation Method 1
the light beams projected onto the container wall area being spaced apart from one another when viewed in an axial direction of the lighting unit
Data Source
Figure 1
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AI summary
The invention relates to a detection system (1) and to an inspection method comprising the detection system (1) for detecting bottles (2) and similar containers (2) that have features arranged on a container wall. The detection system (1) comprises at least one illuminating unit (3) and at least one optical assembly (4) having at least one camera (5), wherein the illuminating unit (3) comprises a plurality of light sources (6) arranged on a plurality of conductive tracks (12), the light sources being arranged one above the other as seen looking in the vertical direction of the illuminating unit, such that by means of the light sources (6) arranged in vertically aligned columns a stripe-shaped light beam (7) can be projected onto a container wall region (8), wherein the respective light beams projected onto the container wall region (8) are spaced from each other, as seen looking in an axial direction of the illuminating unit (3). The detection system (1) is characterised in that the light sources of each conductive track (12) which are arranged in vertically aligned columns, as seen looking in the axial direction, are arranged on said conductive track one above the other without offset, wherein each vertically aligned column (14) of light sources (6) of the respective conductive track (12) can be actuated via a control unit depending on detected surface properties of the container (2) such that the vertically aligned columns (14) are able to project a light pattern onto the container wall region (8) which can be variably adjusted depending on the surface properties.