Glass Bottle Wire Edge Detection via Asymmetric Optical Inspection
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Solution Overview
Problem
The formation of glass bottles can result in 'wire edges' due to excessive force during the pressing process, leading to undesirable thin slivers of molten glass at the sealing surface, which are difficult to detect and may break off.
Innovation Solution
A machine equipped with a conveyor system, light source, beam splitter, field lens, camera, and LED panel to inspect glass bottles for wire edges by illuminating the sealing surface and capturing images to highlight any imperfections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the pressing force is increased to fill the mold completely, then the mold filling is improved, but wire edges are formed at the sealing surface
Solution Approach 1:
The patent changes the lighting parameters (intensity, angle, color temperature) to detect wire edges. The high-intensity light source positioned at a specific angle creates optimal reflection patterns that make wire edges visible to the camera, allowing detection without changing the pressing process parameters
2Device complexity
If conventional inspection methods are used, then the inspection process is simple, but wire edges cannot be detected
Solution Approach 1:
The patent introduces a beam splitter as an intermediary optical element that divides the light path, allowing the camera to capture reflected light from the sealing surface at an optimized angle. This intermediary component enables wire edge detection without requiring complex mechanical inspection apparatus
Solution Approach 2:
The patent replaces mechanical inspection methods with an optical inspection system consisting of light sources, beam splitters, and cameras. This substitution eliminates the need for physical contact or complex mechanical positioning while achieving precise wire edge detection through optical reflection patterns
3Illumination intensity
If the light source illuminates the sealing surface directly, then the sealing surface is visible, but wire edges are not highlighted
Solution Approach 1:
The patent employs asymmetric lighting by positioning the light source at a specific angle (not perpendicular) to the sealing surface. This asymmetric illumination creates differential reflection patterns where wire edges reflect light differently than the surrounding smooth surface, making them visible to the camera positioned at a corresponding angle
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
Effectively detects wire edges by illuminating the sealing surface and capturing images, allowing for the identification and potential removal of undesirable slivers, preventing breakage.
Implementation Method 1
Beneath the glass bottle is a light source 14 which directs light axially through the bottle
Implementation Method 2
through a beam splitter 18, through a field lens 20 and into a camera 22... A vertically oriented LED panel 26 directs light horizontally to the beam splitter 18 which reflects a portion of the light vertically
Implementation Method 3
A vertically oriented LED panel 26 directs light horizontally to the beam splitter 18
Implementation Method 4
through a beam splitter 18, through a field lens 20 and into a camera 22, where the light will be imaged on the camera matrix
Data Source
AI summary
A machine for inspecting glass bottles for wire edges. A bottom light directs light vertically upwardly to image a Camera imaging the glass bottle from above. A beam splitter redirects light from a second light source which issues horizontal light, vertically downwardly towards the sealing surface. The bottle hole appears white, the sealing surface appears gray and the annular step appears black with a wire edge on the step appearing gray.