Container Inspection Fieldbus for Deterministic Sensor-Actuator Timing
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Solution Overview
Problem
Existing inspection systems for containers, particularly in beverage production, face challenges with real-time communication and cost-effective data transmission, especially when handling large volumes of data from multiple sensor and actuator devices, leading to inefficiencies and potential delays in processing and decision-making.
Innovation Solution
The apparatus employs a real-time-capable fieldbus for communication between sensor and actuator devices and a control device, using a single-cable Ethernet-based connection to enable fast and deterministic data transmission, allowing for the processing and transmission of complex data streams with response times under 1 second, and includes a transport device, sensor devices for detecting container characteristics, and actuator devices for discharging faulty containers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If Gigabit Ethernet or Power over Ethernet is used for camera connection, then data transmission capability is improved, but real-time connectivity cannot be guaranteed in every case
Solution Approach 1:
The patent changes the communication parameter from standard Gigabit Ethernet to a real-time capable fieldbus system (such as PROFINET RT/IRT, EtherCAT, or CANopen). This parameter change ensures deterministic data transmission with guaranteed real-time connectivity while maintaining high data transmission capability required for camera systems.
2Measurement precision
If multiple sensor and actuator devices are provided for comprehensive inspection, then inspection quality is improved, but communication complexity and cable requirements increase
Solution Approach 1:
The patent merges multiple communication functions (data transmission, power supply, device control) into a single fieldbus system. This allows multiple sensor and actuator devices to be connected through a standardized communication infrastructure, reducing cable complexity while enabling comprehensive inspection with multiple devices.
Solution Approach 2:
The fieldbus system serves multiple functions simultaneously: it transmits inspection data from sensors, provides power to devices, enables real-time control of actuators, and supports device configuration. This multi-functionality reduces the need for separate cables and systems for each function.
3Loss of information
If complex sensor data is transmitted in real-time from multiple devices, then data completeness is improved, but communication bandwidth requirements and cost increase
Solution Approach 1:
The patent changes the communication protocol parameters to optimize for real-time transmission of complex sensor data. The fieldbus system uses deterministic communication cycles and priority-based data transmission to ensure complete data transfer from multiple sensors without requiring excessive bandwidth, maintaining data completeness while controlling system cost.
Data Source
AI summary
An apparatus for handling, transporting and inspecting containers along a predetermined transport path, having a first sensor device configured for detecting at least one value characteristic of the transported containers, having a first actuator device arranged along the transport path downstream of the first sensor device and configured for acting upon a transported container and a control device that is spaced apart from the sensor and the actuator device is configured for controlling the first actuator device, wherein at least one output by the first sensor device, as a function of the characteristic value, wherein the first sensor device and actuator are in communication with the control device via a cable using a real-time-capable fieldbus, the first sensor device is configured for outputting data, and the communication between the first sensor device, the control device and/or the control device and the first actuator device is in real time.