Inspection Device Functional Check via Projected Test Markings
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Solution Overview
Problem
Existing methods for checking the function of inspection devices in container flow inspection systems are inefficient, prone to manipulation, and pose safety risks, as they rely on marked test containers that must be kept in perfect condition, leading to infrequent quality checks and potential production of defective containers.
Innovation Solution
A method using characteristic test radiation that simulates conditions such as contamination or damage, allowing for functional checks without test containers, by verifying the reaction of the inspection device's radiation source, beam path, and evaluation units, enabling continuous and reliable quality control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If marked test containers are used for functional checks, then the inspection device function can be verified, but the test containers must be kept in perfect condition and the marking area must be excluded from functional checks
Solution Approach 1:
The patent uses test markings that are projected onto containers instead of permanently marked test containers. The projection device creates temporary test markings that can be generated on-demand, eliminating the need to maintain physical test containers in perfect condition while still providing reliable functional verification of the inspection device
Solution Approach 2:
The system uses the production containers themselves as test objects by projecting test markings onto them. This eliminates the need for separate dedicated test containers, allowing the production flow to serve its own testing needs without requiring additional specialized components
2Reliability
If marked test containers are used for functional checks, then the inspection device function can be verified, but manipulation is possible by changing test markings after unsuccessful test runs
Solution Approach 1:
Instead of using physical test containers with permanent markings that can be manipulated, the system projects test markings temporarily onto containers. The projection device can generate standardized test patterns on-demand, making it difficult to manipulate the test markings since they are created electronically rather than physically applied
Solution Approach 2:
The patent replaces the mechanical system of physical test container markings with an optical/electronic projection system. This substitution eliminates the possibility of manually altering physical markings, as the test patterns are generated and projected electronically, providing more secure and reliable functional verification
3Reliability
If marked test containers are used for functional checks, then the inspection device function can be verified, but safety risks exist for operators when inserting test containers
Solution Approach 1:
The system uses the existing production container flow itself for functional testing rather than requiring separate test containers to be inserted by operators. The test markings are projected onto containers already present in the production flow, eliminating the need for operators to handle potentially hazardous test containers
Solution Approach 2:
The patent replaces the mechanical insertion and handling of physical test containers with an optical projection system. The test markings are projected onto containers using light rather than requiring physical contact or insertion, thereby eliminating safety risks associated with operators handling test containers that may contain caustic solutions or other hazards
4Reliability
If marked test containers are used for functional checks, then the inspection device function can be verified, but machine performance must be reduced when inserting test containers
Solution Approach 1:
The system performs functional checks using test markings projected onto containers that are already moving through the production line. This allows functional verification to occur continuously as part of the normal production flow without requiring the machine to stop or reduce speed for separate test container insertion
Solution Approach 2:
The projection device creates test markings on existing production containers rather than requiring separate test containers. This allows the same container to serve both as a production item and a test subject, maintaining continuous production flow while enabling functional verification without performance reduction
5Reliability
If functional checks are carried out every hour using marked test containers, then the inspection device function can be verified, but a large number of containers produced between checks may not meet quality criteria
Solution Approach 1:
The system enables functional checks to be performed continuously as part of the normal production process rather than periodically. By projecting test markings onto containers moving through the production line, the system can verify inspection device function continuously without stopping production, reducing the time between quality checks from hourly to near-real-time
Solution Approach 2:
The projection device allows test markings to be generated on-demand on production containers, enabling frequent functional checks without requiring pre-prepared test containers. This on-demand capability allows the system to perform functional verification at any point in the production flow, effectively reducing the interval between quality checks
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
This approach allows for frequent and reliable functional checks of inspection devices, reducing the risk of defective containers and minimizing production interruptions, while eliminating the need for marked test containers and ensuring operator safety.
Implementation Method 1
an inspection radiation source (3) for illuminating containers (5) to be checked with inspection radiation (7) and a radiation detector (9) for measuring the inspection radiation (7)' after interaction with the container (5)
Data Source
Figure 1A~1B
Figure 2A~2D
Figure 3A~3B
AI summary
The invention relates to a method for checking an inspection device for a product flow. The proper functioning of the inspection device can be checked even without using test containers (5) specially provided for said checking, in that a radiation detector (9) for measuring an inspection radiation after interacting with the products in order to detect a characteristic test radiation (17, 171) is used, and a further check is made as to whether the detected test radiation fulfills a target requirement characteristic of proper functioning of the inspection device.