Automated Plastic Container Inspection via Separation Force
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Solution Overview
Problem
Current quality control methods for plastic container products are time-consuming and costly due to manual testing by trained personnel, which negatively impacts the cost-effectiveness of production and can lead to production of defective products.
Innovation Solution
An automated quality control method where predetermined properties of container products are determined and compared to target values at inspection stations, eliminating the need for manual testing and allowing for real-time optimization of the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual inspection by trained personnel is used to test sample batches, then test results can be obtained with human judgment, but the process is time-consuming and costly
Solution Approach 1:
The patent replaces manual mechanical inspection by trained personnel with an automated testing device that mechanically separates containers from the strip and measures separation force. This substitution eliminates human judgment variability and significantly reduces inspection time while maintaining measurement reliability through automated force detection systems.
Solution Approach 2:
The testing device performs self-inspection by automatically separating containers, measuring separation forces, and determining quality characteristics without requiring external human intervention. The system serves itself by integrating the separation action and measurement function into a single automated process that continuously monitors production quality.
2Adaptability or versatility
If manual inspection is used to determine product properties, then flexibility in handling various container types is maintained, but personnel costs and time consumption increase
Solution Approach 1:
The testing device incorporates dynamic adjustment capabilities that allow it to adapt to different container types and separation methods (twisting, pulling, peeling). The system can modify its separation force application and measurement parameters based on the specific container characteristics, maintaining versatility while operating at high speed to improve productivity.
Solution Approach 2:
The system changes operational parameters such as separation force magnitude, separation speed, and measurement sensitivity based on the container type being inspected. By dynamically adjusting these parameters, the device maintains adaptability across different container designs while operating efficiently at production speeds.
3Productivity
If automated inspection is implemented, then time and personnel costs are reduced, but device complexity increases
Solution Approach 1:
The patent combines the container separation function and the force measurement function into a single integrated testing device. By merging these functions, the system achieves automated inspection with improved productivity while avoiding the complexity of multiple separate systems. The separation mechanism and sensor system work together as a unified apparatus.
Solution Approach 2:
The testing device is designed with universal capabilities to handle different container types and separation methods through a single platform. This multi-functionality reduces the need for multiple specialized devices, thereby managing complexity while maintaining high inspection efficiency across various product lines.
4Ease of operation
If subjective testing by personnel is used, then human expertise can be applied, but measurement reliability is compromised
Solution Approach 1:
The patent replaces subjective human judgment with objective mechanical measurement of separation force. The automated device consistently applies force and measures the exact separation point, eliminating the variability and subjectivity inherent in manual inspection. This substitution significantly improves measurement reliability while keeping the operation simple through automated processes.
Data Source
AI summary
A method establishes the presence of specified characteristics of a container product (9, 11), more particularly of a plastic material. The value of at least one specified characteristic is automatically recorded and compared with the reference value for that characteristic in at least one testing station (1-7) of a testing device.