Optical Format-Part Identification in Container Handling Changeovers
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing container treatment devices face challenges in correctly identifying and assigning interchangeable parts, leading to potential disruptions in production, product quality loss, machine downtime, and damage due to the complexity and risk of incorrect part assignments during product changes.
Innovation Solution
A container treatment device equipped with a control device and a light barrier arrangement that detects and identifies interchangeable parts through unique identification features, such as patterns of holes or edges, allowing for accurate assignment to specific production modes, thereby minimizing errors and reducing changeover times.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If labeling format parts with labels or color codes is used for identification, then format parts can be assigned to production modes, but the assignment process becomes cumbersome and error-prone due to the need for documentation and short installation times in confined spaces
Solution Approach 1:
The patent replaces manual visual identification methods (labels, color codes) with an automated optical sensing system. A light barrier arrangement with sensors automatically detects identification features on format parts during machine operation, eliminating the need for manual documentation reference and visual inspection in confined spaces. This substitution of mechanical/visual identification with automated sensing resolves the contradiction by improving ease of operation while maintaining reliability.
Solution Approach 2:
The format parts themselves carry identification features that enable automatic identification without external documentation or manual intervention. The identification features are integrated directly onto the format parts, allowing the system to self-identify and self-assign the correct parts through automated sensing, thereby simplifying the assignment process while ensuring correctness.
2Adaptability or versatility
If format parts are changed frequently for product changes, then the packaging machine can handle different products, but the risk of operating errors and incorrect assignments increases due to short installation times and confined spaces
Solution Approach 1:
The system implements automated feedback through optical sensors that detect identification features on format parts and provide real-time verification to the control device. This feedback mechanism ensures that only correctly assigned format parts are accepted, preventing operating errors even during frequent changeovers. The feedback loop maintains high reliability while enabling frequent product changes.
Solution Approach 2:
Manual verification and documentation-based assignment methods are replaced with automated optical sensing and electronic control. This substitution eliminates human error in assignment during frequent format part changes, maintaining high reliability while preserving the adaptability needed for frequent product changes.
3Measurement precision
If detailed markings are placed on format parts for identification, then correct assignment can be achieved, but the markings can easily be confused or missed in confined spaces with short installation times
Solution Approach 1:
Visual identification through detailed markings is replaced with automated optical sensing. The light barrier arrangement and sensors detect identification features automatically, eliminating the need for operators to visually interpret markings in confined spaces. This substitution maintains high identification accuracy while dramatically improving ease of operation.
Solution Approach 2:
The identification information is copied from physical markings onto detectable signals through the optical sensing system. The sensors create an electronic copy of the identification features, which is then processed by the control device for accurate assignment. This copying process eliminates the difficulties of direct visual inspection while preserving identification precision.
4Ease of manufacture
If existing sensors are utilized for identification, then cost-effective retrofitting is achieved, but additional identification features must be added to format parts
Solution Approach 1:
Existing sensors in the container handling device are made multi-functional by programming them to detect identification features on format parts in addition to their original functions. This universal utilization of existing sensors enables cost-effective retrofitting without requiring additional sensing hardware, thereby improving ease of manufacture while accepting the addition of identification features on format parts.
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
The solution enables quick, reliable, and error-free identification of interchangeable parts, reducing the risk of machine damage and streamlining the changeover process, while also allowing for cost-effective retrofitting of existing systems by utilizing existing sensors and modifying parts with distinct physical features.
Implementation Method 1
the interchangeable part has at least one identification feature that can be sensed and/or detected by means of a light barrier arrangement
Data Source
Figure 1~2
Figure 3A~3D
Figure 4~5
AI summary
A container handling device (1) and a method for identifying an interchangeable part (10) of a container handling device (1) are disclosed. The container handling device (1) comprises a control unit (5) and at least one interchangeable part (10). The interchangeable part (10) has at least one identification feature (11) that can be detected by a light barrier arrangement (4). The control unit (5) includes information about the at least one interchangeable part (10) and information about different production modes. In addition, the control unit (5) can identify the interchangeable part (10) by means of the data determined by the light barrier arrangement (4) and, in particular, assign it to a specific production mode.