Embossing Inspection via Shadow Imaging for Tobacco Packaging
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Solution Overview
Problem
Existing methods for producing packaging for tobacco products, such as cigarette packs, face challenges in reliably detecting quality and position fluctuations of embossings due to wear on embossing devices and machine cycle tolerances, leading to inconsistent embossing positions and quality.
Innovation Solution
A method and device that use a testing device with an electro-optical camera to record and evaluate shadow images of embossings, allowing for precise determination of embossing positions and quality, adjusting the material web speed to ensure accurate cutting and preventing damage to embossed areas during the packaging process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If embossing devices are used to apply embossings to packaging material, then decorative and informative embossings can be applied to the material web, but wear on the embossing device causes quality fluctuations and position deviations in the embossings
Solution Approach 1:
The patent applies embossings to the material web before the cutting process, and uses sensor detection to identify the actual positions of these embossings. The system then adjusts the cutting process based on the detected positions, compensating for any deviations caused by embossing device wear or material web tension variations.
Solution Approach 2:
The patent employs sensors to detect the actual positions of embossings on the material web and feeds this information back to the control system. The control system uses this feedback to adjust the cutting process, ensuring that cuts are made at the correct positions relative to the embossings despite variations in the embossing process.
2Productivity
If the material web is conveyed through the packaging process with regular tension, then the process is simple and fast, but position deviations occur between the material web and machine cycle elements
Solution Approach 1:
The patent detects the positions of embossings on the material web before the cutting operation and uses this information to pre-adjust the cutting process parameters, ensuring accurate positioning without requiring slow, incremental adjustments during the cutting process itself.
Solution Approach 2:
The patent replaces mechanical positioning methods with an optical sensing and electronic control system. Sensors detect embossing positions optically, and the control system electronically adjusts the cutting process, eliminating the need for complex mechanical positioning mechanisms that would slow down production.
3Productivity
If separating cuts are made based on fixed machine cycle positions, then the cutting process is simple and efficient, but cuts are not made at the correct target positions when material web position deviates
Solution Approach 1:
The patent detects and records the positions of embossings on the material web before the cutting operation, and uses this information to pre-calculate and set the correct cutting positions. This allows the cutting process to proceed efficiently at high speed while ensuring accuracy through advance positioning information.
Solution Approach 2:
The patent uses sensors to detect the actual positions of embossings and feeds this information back to the cutting control system. The control system adjusts the cutting positions based on this feedback, ensuring that cuts are made at the correct locations relative to the embossings even when material web position varies from the ideal position.
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 solution enables reliable detection and correction of embossing position and quality issues, ensuring consistent embossing patterns and preventing damage to embossed areas, thereby improving the packaging process efficiency and product quality.
Implementation Method 1
The test is carried out by illuminating the respective embossing with a lighting device of the testing device in such a way that it casts a shadow image
Implementation Method 2
An electronic image is then recorded of the embossing and of the shadow image of the embossing using an electro-optical testing element of the testing device
Data Source
Figure 1
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AI summary
The invention relates to a method and a device for producing packagings for tobacco products, in particular for cigarette packs, in which packaging material (38) provided with embossings (30, 33-35) is used. The invention is characterised in that the packaging material (38) is conveyed along an inspecting apparatus (45), by means of which at least one of the embossings (30, 33-35) is inspected, in particular with regard to the position or the quality of the embossing (30, 33-35), in that the embossing is illuminated by means of an illuminating apparatus (49) in such a way that the embossing casts a shadow image (51-54"), and in that at least one electronic image of the embossing (30, 33-35) and of the shadow image (51-54") of the embossing (30, 33-35) is recorded by means of an inspecting element (55), preferably an electro-optical camera, and is evaluated in accordance with predetermined criteria.