Filler Machine Inspection With Rotor-Synchronized Imaging
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Solution Overview
Problem
Existing inspection systems for filler devices fail to detect visually recognizable defects such as loss or discoloring of components or adherence of foreign matter on filler machines, requiring manual daily inspection and lacking comprehensive detection capabilities.
Innovation Solution
An inspection device with image capture and computing devices that capture images of filler machines based on rotor coordinates, generating data to identify defects automatically, and includes movable components and environmental protection features to ensure clear imaging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual visual inspection is used to detect defects, then comprehensive defect detection is achieved, but inspection effort and time consumption increase
Solution Approach 1:
The patent replaces manual visual inspection with an automated image-based inspection system. Image capture devices photograph filler machines, and image processing automatically analyzes the images to detect defects such as loss or discoloring of components and adherence of foreign matter. This substitution eliminates manual inspection effort while maintaining comprehensive defect detection capability.
2Extent of automation
If image capture devices are added to automate inspection, then inspection effort is reduced, but device complexity increases
Solution Approach 1:
The patent integrates the image capture device into the existing filler device structure, allowing it to serve both the filling function and the inspection function. The image capture device is positioned to photograph filler machines during their normal operation, and the image processing system utilizes existing coordinate data from the filling control device to locate and analyze specific areas. This integration approach automates inspection while minimizing additional device complexity.
3Reliability
If image capture is performed at all rotor positions, then complete inspection coverage is achieved, but image quality and clarity decrease
Solution Approach 1:
The patent determines in advance, based on rotor coordinate data, which specific positions of filler machines should be photographed. The image capture control device uses this pre-determined information to capture images only at selected positions where defects are most likely to be detected or where critical components are located. This selective imaging approach maintains complete inspection coverage for critical areas while ensuring high image quality by avoiding captures at suboptimal positions.
Data Source
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AI summary
To provide an inspection device configured to easily and comprehensively determine whether a filler device has any visually recognizable abnormality, an inspection device is configured to inspect a filler device, the filler device including: a circular rotor 101 drivable to rotate; a filling control device 102 configured to control operation of the rotor 101; and a plurality of filler machines 103 arranged along a perimeter of the rotor 101, the inspection device including: an image capture device 2 configured to capture an image of each of the plurality of filler machines 103 to generate image data; an image capture control device 5 configured to control the image capture device 2; and a computing device 6 configured to inspect the filler device based on the image data, wherein the image capture control device 5, based on coordinate data on rotating coordinates of the rotor 101 from the filling control device 102, selects a time point at which the image capture device 2 is to generate the image data.