Membrane-Sealed Container Tightness Testing With Optical Profile Detection
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Solution Overview
Problem
Existing methods for testing the tightness of containers sealed by membranes struggle to accurately detect small defects due to insufficient internal pressure increase and time constraints in production line cycles, leading to incomplete detection of small openings or holes.
Innovation Solution
A method and apparatus that applies a deforming action to increase internal pressure, combined with an abutting action to counteract membrane deformation, allowing for a prolonged pressure increase, followed by contactless optical detection of the membrane profile to identify defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a deforming action is applied to increase internal pressure during tightness testing, then the detection capability for small defects is improved, but the production line cycle time is extended
Solution Approach 1:
The deforming action is applied in advance during the handling path before the container reaches the inspection station. This preliminary deformation increases internal pressure ahead of time, so that when air escape detection occurs at the inspection station, the pressure differential is already established, enabling faster detection of small defects without extending the overall cycle time.
Solution Approach 2:
The deforming action is applied periodically during the handling path at specific intervals rather than continuously. This periodic deformation maintains pressure differential during critical detection phases while allowing pressure equalization during transport phases, optimizing both detection capability and cycle time efficiency.
2Measurement precision
If the duration of deforming action is extended to allow complete air escape from small defects, then detection accuracy is improved, but productivity is reduced
Solution Approach 1:
The deforming action is performed in advance during the handling path to establish pressure differential before inspection. This preliminary pressure buildup ensures that even small defects will exhibit air escape during the brief inspection window, maintaining high detection accuracy without requiring extended inspection time that would reduce productivity.
3Reliability
If a load sensor contacts the membrane during transit to detect pressure variations, then tightness testing is performed, but the complexity of the apparatus increases
Solution Approach 1:
The mechanical load sensor contact system is replaced with an optical detection system. Optical sensors non-contactly measure membrane position and deformation, eliminating the need for physical contact sensors. This substitution maintains tightness testing capability while reducing mechanical complexity and potential contamination risks.
Solution Approach 2:
Light serves as an intermediary between the membrane and the detection system. Optical sensors detect membrane deformation and air escape by measuring changes in light reflection or position, rather than directly contacting the membrane with physical sensors. This intermediary approach simplifies the apparatus while maintaining detection reliability.
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 the detection of small defects by increasing internal pressure and facilitating faster air escape from defects, enabling precise classification of tightness without mechanical contact, thus improving defect detection efficiency within production line constraints.
Implementation Method 1
Thanks to this deforming action, the pressure inside the container is increased up to at least a first pressure level when referred to the tightly closed container
Implementation Method 2
Thanks to this abutting action, the pressure inside the container is increased up to at least a second pressure level when referred to the tightly closed container
Implementation Method 3
said detection unit comprises at least one optical detection device for contactlessly measuring said membrane
Data Source
AI summary
A method and relative apparatus for testing the tightness of a container closed by a membrane are described. The method includes steps of: submitting the container to a deforming action to increase the pressure inside the container; submitting the membrane to an abutting action to counteract the deformation of the membrane caused by the deforming action; maintaining the action of abutting the membrane at the same time as the action of deforming the container for a set period of time; interrupting the action of abutting the membrane at the end of the period of time; detecting at least one parameter related to a membrane profile when the abutting action has ceased; and comparing the at least one parameter related to the membrane profile with a predefined threshold to verify whether the tightness of the container is to be classified as defective.