Optical Shape Profile Measurement for Shrink Packaging
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Solution Overview
Problem
Shrink-packaging machines face challenges when packaging objects of different sizes, as they require a large shrink film size to accommodate the largest object, leading to excessive contraction, creases, and material wastage, especially when dealing with transparent or light-absorbing objects, where traditional measurement methods are ineffective.
Innovation Solution
A shape profile measurement device using a light projector and receiver with a movement mechanism, which measures the object's profile by detecting changes in light intensity, allowing for accurate determination of the object's size and shape, even with transparent or light-absorbing materials, and calculates the minimum film length required for wrapping, integrated into a shrink-packaging machine.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a large shrink film size is used to accommodate the largest object, then all objects of different sizes can be packaged, but excessive contraction occurs causing creases and material wastage when packaging small objects
Solution Approach 1:
The system performs preliminary measurement of the object's dimensions using a light projector and receiver before packaging. The object is conveyed through a measurement zone where light is projected to detect its profile, and this pre-measured data is used to calculate the exact shrink film size needed, preventing material wastage while ensuring proper fit for objects of varying sizes
Solution Approach 2:
The system dynamically adjusts the shrink film size parameter based on the measured object dimensions. By changing the film size parameter to match the actual object size rather than using a fixed large size, the system eliminates excessive contraction and material wastage while maintaining adaptability to different object sizes
2Adaptability or versatility
If a large shrink film size is used to accommodate the largest object, then all objects of different sizes can be packaged, but the appearance is degraded due to creases when packaging small objects
Solution Approach 1:
The system performs preliminary measurement of the object's dimensions using a light projector and receiver before packaging. The object is conveyed through a measurement zone where light is projected to detect its profile, and this pre-measured data is used to calculate the exact shrink film size needed, preventing material wastage while ensuring proper fit for objects of varying sizes
Solution Approach 2:
The system dynamically adjusts the shrink film size parameter based on the measured object dimensions. By changing the film size parameter to match the actual object size rather than using a fixed large size, the system eliminates excessive contraction and material wastage while maintaining adaptability to different object sizes
3Measurement precision
If traditional measurement methods are used, then simple objects can be measured, but transparent or light-absorbing objects cannot be accurately measured
Solution Approach 1:
The system replaces traditional mechanical measurement methods with an optical measurement system. A light projector emits light that passes through or reflects off the object, and a light receiver detects the light intensity. This optical method works for all object types including transparent and light-absorbing materials, providing accurate measurements without physical contact
Solution Approach 2:
The system changes the measurement approach from mechanical contact-based measurement to optical non-contact measurement. By using light intensity detection rather than physical sensors, the system can accurately measure transparent and light-absorbing objects that would be difficult or impossible to measure with traditional mechanical methods
4Reliability
If more shrink film is used to ensure proper wrapping, then all objects can be packaged, but material wastage increases
Solution Approach 1:
The system performs preliminary measurement of the object's dimensions using a light projector and receiver before packaging. The object is conveyed through a measurement zone where light is projected to detect its profile, and this pre-measured data is used to calculate the exact shrink film size needed, preventing material wastage while ensuring proper fit for objects of varying sizes
Solution Approach 2:
The system dynamically adjusts the shrink film size parameter based on the measured object dimensions. By changing the film size parameter to match the actual object size rather than using a fixed large size, the system eliminates excessive contraction and material wastage while maintaining adaptability to different object sizes
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
Enables precise measurement of objects' sizes and shapes, optimizing shrink film usage by determining the minimum film length needed, reducing waste and ensuring proper packaging without creases, regardless of the object's material properties.
Implementation Method 1
If the object for measurement is opaque and does not transmit light, the measurement light striking the object for measurement is blocked without reaching the corresponding light-receiving portion... If the object for measurement is transparent, on the other hand, the measurement light striking the object for measurement is transmitted by the object for measurement and reaches the light-receiving portion
Data Source
Figure 1~2
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Figure 5~6
AI summary
To provide a shape profile measurement device capable of measuring a shape profile even of objects that transmit or absorb light. A shape profile measurement device 2 comprises: a light projector 12 and a light receiver 14 arranged facing each other; a belt conveyor 10 for conveying an object O for measurement; and a calculation unit 24. The light projector 12 comprises a plurality of light-emitting portions 16 arranged in an array direction, and each of the light-emitting portions emits substantially parallel measurement light L. The light receiver 14 comprises a plurality of light-receiving portions 18 arranged in the array direction facing the plurality of light-emitting portions, and each of the light-receiving portions receives the measurement light L emitted from a corresponding light-emitting portion. The light-receiving portions 18 output a signal indicating a light intensity of the received measurement light L. The calculation unit 24 acquires the signal of the light receiver 14 when the object O for measurement is at a plurality of different movement-direction positions between the light-emitting portions 16 and the light-receiving portions 18, and obtains a shape profile of the object O for measurement on the basis of the signal acquired and information relating to the plurality of movement-direction positions.