Image-Based Plastic Preform Inspection Before Cooling
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Solution Overview
Problem
Existing systems for producing plastic containers from plastic preforms require more precise monitoring to reduce defects and waste, especially in processes where preforms are produced and formed without excessive heating.
Innovation Solution
A device with integrated inspection devices that record spatially resolved images of plastic preforms between production and cooling stages, allowing for real-time inspection and control of production units and forming stations based on inspection results.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If plastic preforms are produced and formed with less heating, then energy consumption is reduced, but monitoring precision must be increased to ensure fewer defects
Solution Approach 1:
The first inspection device examines plastic preforms immediately after production while they are still warm, detecting defects before the cooling process begins. This preliminary inspection ensures that even with reduced heating, any defects are caught early, maintaining high quality standards while allowing for energy-efficient processing.
Solution Approach 2:
The inspection results from the first inspection device are fed back to control the production device, allowing real-time adjustments to manufacturing parameters. This feedback loop ensures that with less heating applied, the production process can be dynamically optimized to maintain defect levels within acceptable ranges.
2Reliability
If inspection is performed between production and cooling, then defect detection is improved, but production time is increased
Solution Approach 1:
The first inspection device is integrated into the continuous production flow between production and cooling stages. The inspection process occurs without interrupting the overall production sequence, as preforms are inspected while being transported on carriers, maintaining continuous operation and minimizing time loss.
Solution Approach 2:
By performing inspection before the cooling process begins, the system detects defects at the earliest possible moment. This allows for immediate identification and removal of defective preforms, preventing them from progressing through subsequent cooling and forming stages, thereby minimizing the impact on overall production time.
3Manufacturing precision
If multiple inspection devices are integrated into the production line, then quality control is improved, but device complexity is increased
Solution Approach 1:
The inspection system is divided into multiple specialized inspection devices, each positioned at different stages of the production process. The first inspection device focuses on examining preforms after production, while a second inspection device examines preforms after cooling. This segmentation allows each device to be optimized for its specific inspection task, improving overall quality control while maintaining manageable complexity through functional specialization.
Solution Approach 2:
The inspection devices are designed to work within the existing production line infrastructure, utilizing the same transport carriers and integration points. By making the inspection system multi-functional and compatible with the overall production flow, the added complexity is minimized while achieving comprehensive quality control across different production stages.
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
Enhances automation and reduces defects by enabling precise monitoring and control of the production process, improving the quality and efficiency of plastic container manufacturing.
Implementation Method 1
this first inspection device comprises an image recording device which is suitable and intended for recording at least one spatially resolved image of a plurality of plastic preforms
Implementation Method 2
the device further comprises a cooling device for cooling the plastic preforms produced by the manufacturing device
Data Source
Figure 1
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Figure 4
AI summary
Apparatus (101) for producing plastic containers (20), comprising a production device (102) for producing plastic preforms (10) and a forming device (110) which forms the plastic preforms (10) into the plastic containers, wherein the production device (102) has a plurality of production units (103) and the forming device (110) has a plurality of forming stations (112) and a transport device (104, 105, 130) which is suitable and intended to transport the plastic preforms produced by the production device to the forming device (4), wherein the apparatus (1) further comprises a cooling device (106) for cooling the plastic preforms produced by the production device (2), characterized in that the apparatus (1) has a first inspection device (120),which is suitable and intended for inspecting at least one region of the plastic preforms produced by the production device (102), wherein this first inspection device (120) is arranged between the production device (102) and the cooling device (106), and wherein this first inspection device (120) has an image recording device which is suitable and intended for recording a spatially resolved image of a plurality of plastic preforms.