Automated Container Quality Testing via Torque and Weight Measurement
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Solution Overview
Problem
Current quality control methods for container products produced by blow molding, filling, and sealing processes are cumbersome and time-consuming, especially when testing large batches manually, leading to economic inefficiencies and potential subjective errors.
Innovation Solution
A method involving a container belt with separable plastic containers that are automatically separated and tested for properties like weight and torque, allowing for automated recording and comparison to target values, reducing the need for manual personnel and minimizing subjective errors, with additional non-destructive testing methods for wall thickness using ultrasound or optical measurements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual examination of test batches is performed to ensure quality control, then reliable test results can be obtained, but the process becomes time-consuming and increases personnel costs
Solution Approach 1:
The patent replaces manual mechanical examination with automated measurement systems. Sensors and measurement devices automatically record properties such as weight, dimensions, and material characteristics, eliminating the need for manual inspection while maintaining or improving measurement reliability.
Solution Approach 2:
The container production system performs self-inspection through integrated automated measurement devices. The containers themselves are measured by fixed sensors and detectors during or after production, allowing the system to automatically verify quality parameters without external manual intervention.
2Reliability
If manual examination of test batches is performed to ensure quality control, then reliable test results can be obtained, but personnel costs increase
Solution Approach 1:
The patent replaces manual mechanical examination with automated measurement systems. Sensors and measurement devices automatically record properties such as weight, dimensions, and material characteristics, eliminating the need for manual inspection while maintaining or improving measurement reliability.
Solution Approach 2:
The container production system performs self-inspection through integrated automated measurement devices. The containers themselves are measured by fixed sensors and detectors during or after production, allowing the system to automatically verify quality parameters without external manual intervention.
3Productivity
If automated measurement devices are used to improve efficiency, then time and personnel costs are reduced, but the complexity of the production system increases
Solution Approach 1:
The patent divides the measurement system into separate, modular functional units that can be independently implemented. Different measurement devices (weight sensors, dimension detectors, material analyzers) are positioned at specific locations along the production line, allowing incremental implementation and reducing overall system complexity.
Solution Approach 2:
The patent employs measurement devices that can detect multiple properties of the containers using single integrated systems. For example, optical sensors may simultaneously measure dimensions, position, and surface characteristics, reducing the number of separate devices needed and simplifying the overall system architecture.
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
This approach significantly improves economic efficiency by automating quality control, reducing personnel costs, and enhancing the reliability of test results, enabling real-time optimization of the manufacturing process and production parameters.
Implementation Method 1
the containers are separated from the container belt in an independent, preferably first test station by twisting and the torque required for twisting is automatically recorded
Implementation Method 2
the separated containers are mechanically taken to a test station and weighed there for automatic recording of their total weight
Implementation Method 3
the weighed containers are mechanically taken to a test station and emptied there
Implementation Method 4
with additional non-destructive testing methods for wall thickness using ultrasound or optical measurements
Implementation Method 5
with additional non-destructive testing methods for wall thickness using ultrasound or optical measurements
Data Source
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AI summary
Method for establishing the presence of specified characteristics of a container product (9, 11), more particularly consisting of a plastic material, wherein the actual value of at least one specified characteristic is automatically recorded and compared with the reference value for said characteristic in at least one testing station (1-7) of a testing device.