Container Handling Control Using Sensor Drones to Prevent Jams

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing container-handling facilities in the beverage industry face challenges in accurately regulating operating parameters to prevent damage to containers due to indirect forces that are difficult to detect, leading to container jams and damage, especially during mass transport.

Innovation Solution

A container-handling facility equipped with drones that measure acceleration and pressure, transmitting data to a control unit for real-time regulation of operating parameters, including transport device drives and boundary rail adjustments, using a neural network for optimization.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If containers are transported in a mass flow with high number of containers, then productivity is improved, but container damage occurs due to crushing and jamming

Engineering Contradiction:

Improvetransport throughputVSAvoidcontainer damage

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The patent implements a feedback mechanism where sensors detect container position and transport device status in real-time, and the control unit adjusts operating parameters based on this feedback to prevent container damage while maintaining high throughput

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent dynamically adjusts operating parameters such as transport speed and acceleration based on real-time sensor data, allowing the system to optimize between high productivity and container protection by varying parameters according to actual transport conditions

Inventive Principle:

Principle #15Dynamics

2Device complexity

If operating parameters are regulated using commonly used sensors, then device complexity is kept low, but measurement precision is insufficient to detect forces acting on containers

Engineering Contradiction:

Improvesensor system complexityVSAvoidforce detection accuracy

Core Design Contradiction:

Device complexityVSMeasurement precision

Solution Approach 1:

The patent uses the transport device itself as an intermediary measurement platform, where sensors mounted on the transport device measure acceleration and position directly, providing precise force detection without requiring complex external sensor systems

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If inspection units are placed at the end of container handling, then container damage can be detected, but loss of time occurs due to lengthy error analyses and delayed detection

Engineering Contradiction:

Improvecontainer damage detectionVSAvoiderror analysis time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The patent performs preliminary detection of container damage during the transport process itself using sensors on the transport device, rather than waiting until the end of handling, enabling immediate detection and reducing time loss for error analysis

Inventive Principle:

Principle #10Preliminary action

4Stability of the object's composition

If gripping elements apply excessive clamping force, then container stability is improved, but container damage occurs due to crushing and deformation

Engineering Contradiction:

Improvecontainer stabilityVSAvoidcontainer damage

Core Design Contradiction:

Stability of the object's compositionVSObject-affected harmful factors

Solution Approach 1:

The patent dynamically changes the clamping force parameter based on container type, transport phase, and real-time sensor data, adjusting the gripping force to provide sufficient stability without exceeding damage thresholds

Inventive Principle:

Principle #35Parameter changes

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

The solution enables precise and efficient regulation of operating parameters, reducing container damage and improving throughput by adapting to real-time conditions, thus enhancing the reliability and efficiency of container handling.

Implementation Method 1

the drone comprises an acceleration sensor for measuring an acceleration acting on the drone

Methodology Applied

Scientific EffectAcceleration sensing: Accelerometer

Implementation Method 2

a pressure sensor for measuring a pressure acting on the drone in the transport device

Methodology Applied

Scientific EffectPressure sensing: Pressure Increase

Data Source

PatentUS12397955B2Container-handling facility and regulating method

Publication Date: 2025.08.26 KRONES AG

AI summary

Container-handling facility for handling containers such as cans or bottles or the like in the beverage-processing industry, the container-handling facility compris at least one transport device for transporting the containers and a drone can be brought into the transport device, wherein the drone comprises an acceleration sensor for measuring an acceleration acting on the drone and a pressure sensor for measuring a pressure acting on the drone in the transport device, wherein the drone can transmit data corresponding to a measured acceleration and a measured pressure to a control unit, and wherein the control unit is ed to regulate at least one operating parameter influenc the acceleration of the drone and/or the pressure acting on the drone, ding o a comparison between the data received the drone and nominal values for the operating parameter and/or the acceleration and/or the pressure, stored in a memory.