Cap Alignment Inspection Using Dual Imaging on Packaging Lines
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Solution Overview
Problem
Existing capping apparatuses and packaging machines lack an effective means to inspect the alignment and application of opening devices on packages, leading to potential misalignment and improper functioning of caps.
Innovation Solution
An inspection apparatus and method that utilize imaging devices to acquire and analyze images of opening devices before and after application, determining their alignment with designated pour openings, and adjust positions as necessary to ensure precise alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If no inspection apparatus is used, then the device complexity is reduced, but the manufacturing precision of opening device alignment deteriorates
Solution Approach 1:
The inspection apparatus performs preliminary inspection of opening device alignment before the capping operation. By detecting and measuring the position of opening devices on the package main body in advance, the system can identify misaligned packages and prevent defective caps from being applied, thereby ensuring manufacturing precision without requiring complex real-time adjustment mechanisms.
Solution Approach 2:
The patent replaces complex mechanical alignment adjustment mechanisms with an optical inspection system. Instead of using mechanical sensors or actuators to detect and correct alignment, the invention uses imaging devices (cameras) and image processing to detect the position of opening devices and determine alignment status, simplifying the overall system while maintaining high precision.
2Reliability
If inspection apparatus is added, then the reliability of cap function is improved, but the device complexity increases
Solution Approach 1:
The inspection apparatus provides feedback information about the alignment status of opening devices to the capping apparatus. By detecting the actual position of opening devices and comparing it with the expected position, the system can generate feedback signals that control the capping operation, ensuring reliable cap function while maintaining system simplicity through automated feedback control.
Solution Approach 2:
The inspection system creates optical copies (images) of the opening devices and package main bodies for analysis. Instead of directly measuring alignment with complex mechanical sensors, the system uses imaging devices to capture visual information and processes these copies to determine alignment status, reducing hardware complexity while improving reliability.
3Measurement precision
If imaging devices are used for inspection, then the measurement precision of alignment is improved, but the use of energy increases
Solution Approach 1:
The inspection apparatus operates periodically rather than continuously. Imaging devices capture images at specific stages of the packaging process (e.g., when the package main body passes through the inspection station), and image processing is performed only when new data is available. This periodic operation significantly reduces energy consumption compared to continuous monitoring, while maintaining high measurement precision through targeted imaging at critical alignment points.
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 high-precision inspection of opening device alignment, identifying and preventing misaligned packages from being delivered, thereby ensuring proper cap function and product quality.
Implementation Method 1
a first imaging device (31) positioned at a first inspection station (32) and configured to acquire a first image (33) of an imaging portion (34) of the main body (4)
Data Source
Figure 1
Figure 2~3B
AI summary
There is described an inspection apparatus (30) for inspecting opening devices (5) applied to main bodies (4) advancing along an advancement path (P). The inspection apparatus (30) comprises a first imaging device (31) positioned at a first inspection station (32) and configured to acquire a first image (33) of an imaging portion (34) of the main body (4), the imaging portion (34) having a designated pour opening area (9) of each main body (4), a second imaging device (35) positioned at a second inspection station (36) arranged downstream from the first inspection station (32) and configured to acquire at least one second image (37) of the respective opening device (4) applied to the respective inspection portion (34) and an analyzing unit (38) configured to analyze each first image (33) and the respective second image (38) and to determine a relative position between each opening device (5) and the respective designated pour opening area (9) from the analysis of each first image (33) and the respective second image (37).