Image-Based Recipe Recognition for Packaging Machine Changeovers
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Solution Overview
Problem
Packaging and food processing machines face inefficiencies due to complex configuration parameters, leading to confusing and error-prone recipe selection, longer changeover times, and increased machine downtimes, which can result in incorrect adjustments and reduced efficiency.
Innovation Solution
An industrial machine equipped with an image capture unit, classification unit, and control unit that uses a classification model to automatically identify products and select appropriate processing recipes based on captured electronic image data, thereby simplifying and automating the recipe selection process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual recipe selection is used on the user interface, then the machine can be configured for different products, but the process becomes confusing, slow, and error-prone
Solution Approach 1:
The patent replaces the manual mechanical interaction (user navigating menus on a touchscreen interface) with an automated optical recognition system. Cameras capture images of products on the conveyor belt, and image processing algorithms automatically identify product types and select appropriate recipes, eliminating the need for manual interface interaction and significantly reducing changeover time
Solution Approach 2:
The system enables the machine to automatically identify products and select recipes without human intervention. The image capture unit and classification algorithm work autonomously to detect product characteristics and configure machine parameters, allowing the system to serve itself in the recipe selection process
2Adaptability or versatility
If multiple recipes are stored for different products, then the machine can process various products, but the recipe selection becomes confusing and error-prone
Solution Approach 1:
The patent replaces error-prone manual recipe selection with automated image-based product recognition. The system captures images of products, processes them through classification algorithms, and automatically selects the correct recipe based on identified product characteristics, eliminating human error in recipe selection
Solution Approach 2:
The system establishes a feedback loop where product images are continuously captured during conveyor operation, classified in real-time, and used to automatically adjust machine configuration. This closed-loop approach ensures the correct recipe is selected based on actual product presence rather than manual selection
3Ease of operation
If the machine is manually configured for each product change, then the operating parameters can be adjusted, but the configuration work is considerable and time-consuming
Solution Approach 1:
The system automatically performs the configuration work that previously required manual intervention. Image processing algorithms identify products and the control system automatically adjusts operating parameters based on the identified product type, eliminating the need for operators to manually configure machine settings for each product change
Solution Approach 2:
The system performs recipe selection and parameter configuration in advance based on product identification, so that when a product change occurs, the machine is already configured and ready to process. This preliminary automatic configuration eliminates downtime associated with manual setup
Data Source
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AI summary
An industrial machine configured for food processing or as a packaging machine comprises a feed unit, an image acquisition unit, a classification unit, and a control unit. The feed unit is configured to feed products to the industrial machine for processing. The image acquisition unit is configured to capture electronic image data depicting a product. The image data is captured while the product is located in the feed unit. The classification unit is configured to assign a product classification corresponding to the depicted product to the image data, wherein assigning the product classification comprises applying a classification model to the image data.The control unit is configured to determine, based on the product classification, from a plurality of predefined processing recipes, those that are configured for processing the product with the industrial machine and to designate one of the determined processing recipes as the configuration recipe. The control unit is further configured to adapt the industrial machine for processing the product according to the configuration recipe.