Dynamic Force Control for Soft Tray Seal Inspection
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Solution Overview
Problem
Trays with soft raw materials used in top-sealed packages are at risk of damage or product deformation due to excessive pressure during inspection, as existing inspection methods apply uniform and potentially excessive force.
Innovation Solution
A seal checking apparatus with a contact component that adjusts its force and height position dynamically, using a raising/lowering unit and a control unit to apply a second force that is different from the initial force, thereby minimizing pressure on the tray and preventing damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a strong pressing force is applied to detect defective packages, then the detection reliability is improved, but soft trays may be damaged or the product inside may be deformed
Solution Approach 1:
The pressing force is made dynamic rather than static. The pressing member applies a time-varying force profile: initially applying a relatively strong pressing force to ensure reliable detection of defective packages, then gradually reducing the force to a maintenance level that prevents tray damage while maintaining seal integrity. This dynamic force adjustment resolves the contradiction between detection reliability and tray protection.
Solution Approach 2:
The pressing operation is divided into distinct phases: an initial pressing phase with higher force for detection, followed by a maintenance phase with reduced force. This periodic action pattern allows the system to achieve both strong initial contact for reliable detection and sustained gentle pressure to prevent damage during the inspection period.
2Ease of operation
If a uniform pressing force is applied to all trays, then the inspection process is simplified, but trays with different materials may be damaged due to excessive pressure
Solution Approach 1:
The pressing force parameter is made variable rather than fixed. The system changes the magnitude of the pressing force based on the specific tray being inspected, applying stronger forces to rigid trays and softer forces to flexible trays. This parameter adjustment allows the system to maintain simplicity in operation while adapting to different tray materials to prevent damage.
Solution Approach 2:
The system incorporates feedback mechanisms to monitor tray response during pressing. By detecting the degree of tray deformation or resistance, the system automatically adjusts the pressing force to appropriate levels, preventing excessive pressure on soft trays while maintaining effective inspection pressure on rigid trays.
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 apparatus effectively suppresses the force exerted on the tray during inspection, preventing damage and ensuring the integrity of both the tray and the product, while allowing for appropriate force application based on tray type and material.
Implementation Method 1
The detection unit detects an amount of displacement in the height position of the contact component when the tray is touching the contact component
Implementation Method 2
a downward force caused by gravity and an upward force caused by the raising/lowering unit act on the contact component
Implementation Method 3
The raising/lowering unit changes the height position of the contact component
Implementation Method 4
When the contact component touches the film of the tray, the control unit changes a first force to a second force to thereby cause pressure to be exerted from the contact component to the film of the tray
Data Source
Figure 1
Figure 2
Figure 3A
AI summary
In a seal checking apparatus, a detection unit detects an amount of displacement in a height position of a contact component when a tray is touching the contact component. An inspection unit inspects a sealed state of a film by comparing the amount of displacement with a threshold. A control unit causes the contact component to stand by in a first height position higher than a height position of a rim of the tray and, when the tray is transported thereto, changes a force that a raising/lowering unit applies to the contact component to thereby lower the contact component from the first height position toward a predetermined second height position. When the contact component touches the film of the tray, the control unit changes a first force to a second force to thereby cause pressure to be exerted from the contact component to the film of the tray. The first force is the force that the raising/lowering unit had been applying to the contact component before the contact component touched the film of the tray. The second force is a force different from the first force.