Faulty Object Selection System with Segmented Rejection
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Solution Overview
Problem
Existing systems for removing faulty containers from high-speed packaging lines, such as those in the food and beverage industry, fail to accurately identify and separate faults like cracks, chipping, air bubbles, and opacity, making it difficult to trace the origin of defects and prevent their recurrence.
Innovation Solution
A system comprising an inlet and outlet conveyor, an inspection unit with camera sensors, and a selecting and removing unit with grippers and slides that classify and selectively remove faulty objects based on detected faults, allowing for detailed analysis of fault types and positions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If single-acting pneumatic ejectors are used to remove faulty containers, then the containers are removed from the production line, but it becomes extremely difficult to evaluate and track the faults to their origin
Solution Approach 1:
The patent divides faulty containers into separate collection channels based on fault type and location. Multiple rejection fingers are positioned at different locations along the production line, each directing faulty containers to specific collection zones. This segmentation preserves fault information by spatially separating different fault types, enabling subsequent analysis and tracking of fault origins.
2Productivity
If progressive rejection systems with multiple fingers are used, then faulty containers are removed effectively, but the containers are collected without being divided, making fault analysis impossible
Solution Approach 1:
The patent implements segmentation by creating distinct collection zones for different fault types. Rejection fingers are strategically positioned to direct containers with specific faults to predetermined collection areas, thereby classifying faults spatially. This enables precise fault analysis while maintaining effective removal of all faulty containers.
Solution Approach 2:
The patent introduces intermediate collection zones as mediators between the rejection system and final collection. These zones act as temporary holding areas that preserve the spatial relationship between fault type and collection location, enabling subsequent analysis of fault patterns and origins without interfering with the high-speed rejection process.
3Productivity
If high-speed production lines operate at tens of thousands of packages per hour, then productivity is maximized, but the risk of imperfections increases significantly
Solution Approach 1:
The patent implements continuous quality inspection and rejection along the entire production line. Multiple inspection and rejection systems operate simultaneously at different stages, ensuring that every container is checked without interrupting the high-speed production flow. This continuous action maintains both high productivity and quality by immediately removing faulty containers while they pass through the production line.
Solution Approach 2:
The patent performs preliminary rejection of obviously faulty containers at early stages of the production line, before they undergo further processing. This preliminary action reduces the burden on subsequent inspection stages and prevents potentially faulty containers from progressing further, thereby maintaining high overall quality while preserving production speed.
Data Source
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AI summary
The present invention relates to a system for inspecting and selecting objects, in particular for a system for selecting faulty containers in packaging plants. In particular, the present invention relates to a system for inspecting and selecting (1) faulty objects in a production line and/or for packing said objects (B), comprising an inlet conveyor (2), an outlet conveyor (3), an inspection unit (4) and a selecting and removing unit (5) of the faulty objects, characterized in that the inlet (2) and outlet (3) conveyors are aligned along a path of the objects and separated by a space, in which the selecting and removing unit (5) is arranged, the selecting and removing unit (5) being configured, so as to constitute a transport joining section of the objects (B) between the two conveyors (2, 3) and in that the selecting and removing unit (5) of the faulty objects comprises a handling device (7) of the objects (B) comprising a plurality of grippers (14) configured to handle said objects (B).