Container Denester Vision Counting System
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Solution Overview
Problem
Conventional denesting machines require manual recalibration and downtime when handling different stacks of containers from various vendors due to reliance on distance settings, which is inefficient and costly.
Innovation Solution
A machine equipped with a counting device, such as a camera or vision system, automatically sets the distance setting by counting the exact number of containers, allowing for precise separation of a predetermined number of containers from a stack, regardless of shape or size, using a piercing blade and servo motor to implement the separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If distance setting is used to separate containers, then the separation function is achieved, but the machine requires shutdown and recalibration when handling different vendor containers, resulting in downtime and inefficiency
Solution Approach 1:
The patent replaces the mechanical distance-setting system with an optical vision system and automated control system. The vision system captures images of the container stack, automatically counts containers, and calculates the precise insertion depth needed, eliminating the need for manual mechanical adjustment and recalibration when handling different vendor containers.
Solution Approach 2:
The machine performs self-calibration through automated container counting and depth calculation. The vision system automatically adapts to different container types by counting the actual number of containers in the stack and computing the required piercing depth, without requiring operator intervention or machine shutdown.
2Manufacturing precision
If manual distance adjustment is performed for each vendor, then accurate separation is achieved, but the operation becomes complex and time-consuming
Solution Approach 1:
The patent replaces complex manual mechanical adjustment with an automated vision-based measurement and control system. The system uses image processing to automatically determine container dimensions and stack configuration, then calculates and executes the precise piercing depth automatically, maintaining high separation accuracy while eliminating complex manual operations.
Solution Approach 2:
The vision system performs preliminary measurement and calculation of the required piercing depth before the actual separation action. By capturing images and computing the optimal insertion depth in advance, the system ensures accurate separation without requiring complex real-time adjustments during operation.
3Manufacturing precision
If the machine shuts down for recalibration, then accuracy is maintained for new container types, but productivity decreases due to downtime
Solution Approach 1:
The patent enables continuous operation by maintaining the vision system and automated control active throughout the process. The system continuously captures images, counts containers, and adjusts piercing depth automatically without shutting down, ensuring both accuracy and uninterrupted productivity when handling different vendor containers.
Solution Approach 2:
The machine performs self-adjustment of piercing depth parameters in real-time based on vision system measurements of the actual container stack. This automatic adaptation maintains counting accuracy for different container types without requiring shutdown for recalibration, thereby preserving continuous productivity.
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 efficient and cost-effective separation of containers by eliminating the need for manual recalibration, ensuring consistent output and improving count accuracy, as the machine can adapt to different container types and sizes without downtime.
Implementation Method 1
The counting device may comprise a camera, a vision system, a piezoelectric sensor, or a mechanical limit switch
Implementation Method 2
The counting device may comprise a camera, a vision system, a piezoelectric sensor, or a mechanical limit switch
Data Source
AI summary
An apparatus that denests a stack of containers and methods of separating a stack of containers and making the apparatus are disclosed. The apparatus includes a denester and a counting device. The denester is configured to separate a first stack of at least 2 containers into a plurality of second stacks of containers. Each of the second stacks includes an exact number of containers, the exact number being a positive integer less than m. The counting device is configured to count the exact number of containers in the first stack. The method of separating containers includes counting an exact number of containers in a first stack of m containers using the counting device, and separating the exact number of containers from the first stack using the denester.