Carton Package Stiffness Classification for Leak Detection
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Solution Overview
Problem
Existing package classification technologies, such as vision sensors and manual assessment, struggle to reliably detect deficiencies in packages that affect food safety, particularly in carton packages subjected to steam or water treatment, and are costly or inconsistent.
Innovation Solution
A method and apparatus that apply forces to carton packages to measure deformation, distinguishing between packages that have leaked water and those that have withstood steam treatment by classifying based on stiffness, using a conveyor system with arms and rotary encoders to assess deformation against threshold intervals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If vision sensor technology is used to detect package deficiencies, then detection speed is improved, but detection reliability deteriorates because deficiencies affecting food safety are difficult or impossible to detect from image data alone
Solution Approach 1:
The patent introduces an intermediary mechanical testing device that applies controlled forces to the package and measures deformation responses. This intermediary system bridges the gap between visual inspection and actual package integrity assessment, enabling reliable detection of food safety deficiencies that vision sensors cannot detect from images alone.
Solution Approach 2:
The patent replaces manual mechanical testing with an automated mechanical testing system that applies forces and measures deformations. This substitution maintains high detection reliability while improving speed and consistency compared to manual assessment, resolving the contradiction between automation speed and reliable detection.
2Reliability
If manual assessment stations are used to assess packages, then detection reliability is improved, but operational costs increase and consistency deteriorates due to operator variability
Solution Approach 1:
The mechanical testing device performs self-assessment of package integrity by automatically applying forces and measuring deformations without human intervention. The system classifies packages based on measured deformation values, eliminating operator variability and reducing operational costs while maintaining consistent, reliable detection across all packages.
Solution Approach 2:
The patent replaces manual mechanical assessment with an automated mechanical testing system that objectively measures package deformation. This substitution eliminates the need for human operators, ensuring consistent and reliable detection while reducing operational costs and improving ease of operation.
3Reliability
If forces are applied to measure package deformation, then classification reliability is improved, but device complexity increases
Solution Approach 1:
The patent segments the classification process into distinct functional modules: a conveyor system for transporting packages, a forcing mechanism for applying controlled forces, a measurement system for detecting deformations, and a classification unit for evaluating results. This segmentation manages device complexity by organizing functions into separate, manageable components while maintaining high classification reliability.
Solution Approach 2:
The mechanical testing device is designed with universal applicability to detect various types of package deficiencies affecting food safety, including seal integrity, package strength, and structural soundness. This multi-functionality achieves reliable classification across different deficiency types without proportionally increasing device complexity.
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 approach provides reliable and cost-effective classification, ensuring packages meet quality standards and reducing the risk of food contamination, while allowing for efficient throughput during the classification process.
Implementation Method 1
measuring a deformation of the package caused by the force
Implementation Method 2
classifying the packages by using a method of classifying each a package of the packages based on stiffness of the package
Data Source
Figure 1~2
Figure 3
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AI summary
A method (400) of classifying a package (102) based on stiffness of the package (102), wherein the package (102) comprises carton and is filled with food product, said method comprises applying (402) a force (F1) on the package (102), retrieving (404) a sample value by measuring (414) a deformation of the package (102) caused by the force (F1), determining (406) a difference (408) between the sample value and a reference value, and classifying (408) the package (102) as belonging to a first category if the difference is within a threshold interval, otherwise classifying (410) the package (102) as belonging to a second category.