Contactless Leak Test for Plastic Bottles Using Pressure Pulses
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Solution Overview
Problem
Existing leak test methods for plastic bottles are not suitable for continuous processing, often requiring interruption of the bottle flow and consuming excessive pressure medium while producing noise, and are ineffective in detecting leaks or improper sealing without disrupting the flow.
Innovation Solution
A contactless leak test system using an optoelectric detection system and pressure medium system with a controllable valve, generating brief pressure medium pulses to apply punctiform loads on the bottle wall, combined with an evaluation unit that compares actual indentation data with reference data to determine if the bottle is sealed, allowing for real-time sorting of defective bottles without interrupting the flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If mechanical compression is used to perform leak tests on plastic bottles, then the leak detection is possible, but the bottle flow must be interrupted and the process cannot be integrated into continuous production
Solution Approach 1:
The patent replaces mechanical compression systems with a contactless pressure medium pulse system. Instead of mechanically compressing the bottle, a pressure medium (gas or liquid) is transmitted through a nozzle to create a punctiform load on the bottle wall, eliminating the need for mechanical contact and allowing continuous processing
Solution Approach 2:
The patent employs periodic pulsed action by generating brief pressure medium pulses (duration: 1-10 ms) rather than continuous pressure application. This pulsed approach allows the bottle to return to its original state between pulses, enabling continuous flow while maintaining detection reliability
2Productivity
If contactless pressure control with fluid jets is used to test containers, then continuous processing is possible, but excessive pressure medium is consumed and noise is produced
Solution Approach 1:
The patent uses periodic pulsed action with brief pressure medium pulses (1-10 ms duration) instead of continuous fluid jet application. This reduces pressure medium consumption significantly while maintaining the ability to detect leaks through the induced deformations
Solution Approach 2:
The patent applies local quality by directing the pressure medium through a nozzle to create a concentrated punctiform load at a specific location on the bottle wall, rather than applying pressure uniformly. This localized approach reduces overall pressure medium consumption while maintaining detection effectiveness
3Productivity
If contactless pressure control with fluid jets is used to test containers, then continuous processing is possible, but noise is produced that interferes with detection
Solution Approach 1:
The patent employs periodic pulsed action with very brief pressure medium pulses (1-10 ms), which minimizes the duration of noise generation. The brief pulse duration reduces noise accumulation while still providing sufficient time for the detection system to capture the deformation and identify leaks
4Measurement precision
If complex measurement structures with multiple sensors are installed to detect deformations, then leak detection accuracy is improved, but the device complexity increases
Solution Approach 1:
The patent uses optical measurement systems (such as laser triangulation or structured light) that create optical copies or images of the bottle surface deformation. This allows precise measurement of the deformation pattern caused by the pressure medium pulse without requiring complex mechanical sensor arrays, simplifying the overall device structure while maintaining measurement precision
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 reliable detection of leaking or improperly sealed plastic bottles with reduced noise and pressure medium consumption, ensuring continuous bottle flow and precise sorting of defective bottles, even at high speeds.
Implementation Method 1
at least one or more pressure medium pulses having variable durations of, for example, 1 ms to 6 ms are generated when the plastic bottle is led past a nozzle of the pressure medium system, wherein the at least one or each pressure medium pulse applies a punctiform load on a bottle wall region
Implementation Method 2
at least one light source of the detection system illuminates at least the bottle wall region loaded by the pressure medium pulse at the same time as the pressure medium pulse is generated, wherein the detection system or a camera thereof receives data of the bottle wall region loaded with the pressure medium pulse
Data Source
AI summary
The invention relates to a leak test for filled and closed plastic bottles (5), wherein the plastic bottles (5) are led past a testing device (9) in a positionally stable manner, wherein the testing device (9) comprises an (optoelectric) detection system (10) and a pressure medium system (11), wherein the detection system (10) and at least one controllable valve (17) of the pressure medium system (11) are connected to an evaluation and control unit (15), wherein at least one or more pressure medium pulses having variable durations or a duration of 1 ms to 6 ms are generated when the plastic bottle (5) is led past a nozzle (16) of the pressure medium system (11), wherein each pressure medium pulse applies a punctiform load on a bottle wall region (18), wherein at least one light source (12, 13) or a laser beam of a laser distance sensor (23) of the detection system (10) illuminates or irradiates at least the bottle wall region (18) loaded by the pressure medium pulse at the same time as the pressure medium pulse is generated, wherein a camera (14) or the laser distance sensor (23) of the detection system (10) receives data of the bottle wall region (18) loaded with the pressure medium pulse and transmits the data to the evaluation and control unit (15). The invention provides for contactless pressure control of filled and closed plastic bottles (5), having a reduced pressure medium consumption and producing less noise.