Mold Origin Identification for Container Sorting
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Solution Overview
Problem
In glassware manufacturing, variations in molds lead to non-compliant products, making it challenging to detect and address commercial variations in a timely manner, resulting in the production of unacceptable containers.
Innovation Solution
A system and method for inspecting and sorting molded containers that includes an inspection device, a mold origin identifier, and a controller to monitor commercial variations, segregating containers produced by molds exceeding acceptable limits, and automatically rejecting or re-routing containers from problematic mold cavities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If automated inspection and sorting is implemented to identify containers with commercial variations, then product quality consistency is improved, but device complexity increases
Solution Approach 1:
The system divides the inspection process into distinct functional modules: inspection device for detecting commercial variations, mold origin identifier for tracing containers to specific molds, controller for analyzing data and making decisions, and diverter for physical segregation. This segmentation allows each component to perform its specific function efficiently while maintaining overall system manageability despite the complexity of the complete inspection and sorting system.
2Loss of time
If real-time monitoring and segregation of non-compliant containers is implemented, then loss of time for detecting mold problems is reduced, but productivity is affected due to segregation operations
Solution Approach 1:
The system performs preliminary identification and segregation of containers with commercial variations immediately after inspection, before they proceed further down the production line. By implementing real-time monitoring and instant segregation through the diverter mechanism, the system detects mold problems at the earliest possible moment, preventing continued production of defective containers while minimizing disruption to overall production flow.
3Ease of operation
If automated apparatus is used to feed glass gobs to molds and convey containers for inspection, then ease of operation is improved, but device complexity increases
Solution Approach 1:
The automated apparatus integrates multiple functions into unified systems: the inspection device not only detects commercial variations but also provides data to the controller for mold identification and decision-making; the diverter system both segregates non-compliant containers and provides feedback to the control system; the mold origin identifier traces containers back to specific molds while enabling targeted interventions. This multi-functionality reduces the need for separate dedicated devices for each operation.
Data Source
AI summary
An apparatus and method for inspecting and sorting molded containers includes an inspection device for inspecting containers and a container mold of origin identifier for correlating a container that is determined to have at least one unacceptable commercial variation with the mold cavity that produced the container. A controller having a programmed cavity reject threshold is in communication with the inspection device and the container mold of origin identifier for monitoring a commercial variation threshold to determine if a mold of origin has produced a threshold number of containers having a commercial variation outside the acceptable limits. A diverter is in communication with the controller for segregating all the containers produced by a mold of origin determined to have produced the threshold number of containers having the commercial variation beyond the acceptable limits.