Container Orientation Detection Upstream of Carousel
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Solution Overview
Problem
Existing container processing machines face challenges with increased dimensions, complexity, and costs due to multiple sensors and brackets on carousels, as well as inefficiencies in detecting container orientation, particularly for containers with caps or top markings.
Innovation Solution
A machine with a detector positioned upstream of the carousel to detect container orientation from the side or top, using a synchronized transfer starwheel and carousel system that maintains container orientation and rotates supports to align with detected markings without full rotation, reducing the need for extensive sensor arrays and optimizing detection timing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If multiple sensors and brackets are mounted on the carousel to detect container orientation, then detection accuracy is improved, but device complexity and carousel dimensions increase
Solution Approach 1:
The detection function is extracted from the carousel structure and relocated to a fixed position upstream. The detector is positioned outside the carousel, eliminating the need for multiple sensors and brackets to be mounted on the rotating carousel, thus reducing device complexity while maintaining detection accuracy
Solution Approach 2:
The detection approach transitions from radial detection (multiple sensors around the carousel perimeter) to axial detection (single detector positioned upstream). This dimensional change allows a single detector to capture container orientation information before the container enters the carousel, simplifying the overall system structure
2Measurement precision
If multiple sensors are distributed around the carousel perimeter, then container orientation can be detected at any position, but manufacturing cost and device complexity increase
Solution Approach 1:
The detection function is extracted from the carousel and placed in a fixed upstream position. This eliminates the need for multiple expensive sensors distributed around the carousel, reducing manufacturing costs while maintaining the ability to detect container orientation
Solution Approach 2:
Container orientation is detected in advance upstream of the carousel, before the container enters the processing stations. This preliminary detection allows the system to plan and execute precise orientation adjustments without requiring multiple sensors during carousel rotation, reducing overall system cost
3Measurement precision
If the carousel radius is increased to allow full container rotation for detection, then orientation detection is improved, but productivity decreases due to longer detection time
Solution Approach 1:
Container orientation and spot position are detected upstream before the container enters the carousel. This preliminary detection eliminates the need for the container to complete a full rotation during processing, as the required orientation can be calculated in advance and the carousel can be synchronized to deliver the container at the correct angle, thereby improving productivity
Solution Approach 2:
The system dynamically adjusts the carousel rotation speed and position based on the detected container orientation and spot location. Instead of requiring fixed full rotations, the carousel can be accelerated or decelerated to deliver containers at optimal angles, maintaining detection accuracy while improving throughput
4Measurement precision
If brackets are distributed around the carousel for sensor support, then detection coverage is improved, but maintenance accessibility deteriorates
Solution Approach 1:
The detector is extracted from the carousel structure and positioned in a fixed upstream location. This eliminates the need for brackets distributed around the carousel, providing clear access to all carousel components for maintenance and repair while maintaining full detection coverage through the upstream positioning
Data Source
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AI summary
Described is a machine (1) for moving containers (2) to be processed along a feed path, comprising infeed means (3) for feeding the containers (2) to an infeed station (4) and an infeed transfer unit (5) configured to pick up one container (2) at a time and carry it to a loading station (6) of a carousel (12). The carousel (12) comprises a plurality of supports (14) for the containers (2). More specifically, the machine (1) comprises a detector (19) configured for detecting an initial orientation of each container (2) and a control unit configured for calculating the angle of rotation of the support (14) in order to orient the container (2) loaded on it in a final predetermined orientation as a function of the initial orientation detected and the movement by the transfer unit, and for rotating the support (14) by the calculated angle of rotation.