Optical Thread Position Detection for Container Alignment
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Solution Overview
Problem
Current mechanical and optical solutions for aligning preforms require additional effort and expense due to the need for precise sensor setup and special preforms with markings, leading to increased overhead and errors during container manufacturing, especially when changing die types.
Innovation Solution
An optical thread position detection device using optical detection devices, a processor, and positioning systems to align containers' longitudinal axes, eliminating the need for mechanical contacting and special preforms by utilizing standard preforms and non-contact position determination, allowing for precise and cost-effective detection of thread positions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If mechanical solutions with notches or cams are used to align preforms, then alignment precision is improved, but manufacturing cost and device complexity increase due to special preforms and mechanical components
Solution Approach 1:
The patent replaces mechanical alignment systems (notches, cams, physical markers) with an optical detection system using cameras and image processing. The camera captures images of the preform's threaded section, and software automatically detects thread position and orientation, eliminating the need for mechanical alignment features on the preform itself.
Solution Approach 2:
The patent creates a digital copy (image) of the preform's physical features and processes this copy through image recognition algorithms. Instead of physically interacting with the preform's alignment features, the system captures optical information and processes it computationally to achieve alignment, reducing the need for special mechanical preform features.
2Manufacturing precision
If optical solutions with cameras and sensors are used for alignment, then alignment capability is improved, but device complexity and setup effort increase due to precise sensor positioning requirements
Solution Approach 1:
The patent designs the optical detection device to be universally applicable to different preform types and threaded sections. The camera system and image processing algorithms can detect various preform geometries without requiring repositioning or recalibration, making the device adaptable to multiple container types and production scenarios.
Solution Approach 2:
The system performs automatic image capture and processing without requiring manual intervention for sensor positioning or calibration. The camera automatically captures images of the preform, and the image processing software autonomously detects thread position and orientation, eliminating the need for operators to manually adjust sensors for each preform type.
3Measurement precision
If special preforms with markings are used for detection, then detection accuracy is improved, but product cost increases due to additional manufacturing requirements
Solution Approach 1:
The patent replaces physical markings on preforms with optical detection of the preform's inherent geometric features, specifically the threaded section. The camera system detects thread position and orientation based on the preform's standard manufacturing features, eliminating the need for additional markings, notches, or cams that would increase preform manufacturing complexity and cost.
4Reliability
If mechanical contacting methods are used for alignment, then alignment reliability is improved, but productivity decreases due to mechanical stress and slower processing
Solution Approach 1:
The patent replaces mechanical contacting alignment methods with a non-contact optical system. The camera captures images of the preform's threaded section from a distance, and image processing algorithms determine thread position without physical contact. This eliminates mechanical stress on the preform and enables faster processing speeds, improving both reliability and productivity.
Solution Approach 2:
The optical detection system enables continuous, high-speed image capture and processing as preforms move through the production line. Unlike mechanical systems that require stopping or slowing for alignment, the optical system can detect and process thread position information continuously, maintaining production flow and increasing overall machine performance.
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 solution enables precise, cost-effective, and secure detection of thread positions, increasing machine performance and simplifying production changes, as it does not require mechanical contacting or special preforms, and allows for high throughput without inducing mechanical stress on containers.
Implementation Method 1
the optical detection device (4a, b) being set up and provided for the purpose of receiving position values and information on at least one relative rotational position of at least one threaded section (2a)
Data Source
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AI summary
The optical thread position detection device (1) for detecting rotational position of threads of containers (3), comprises an optical detector (4a), a processor device (12), a positioning device for a defined orientation of a longitudinal axis of the containers relative to the detector, and an activation unit for triggering the detector. The positioning device and a defined coupling area of the container are connectable to one another. The optical detector, without coming into contact, registers items of information on the relative rotational position of a thread portion (2a). The optical thread position detection device (1) for detecting rotational position of threads of containers (3), comprises an optical detector (4a), a processor device (12), a positioning device for a defined orientation of a longitudinal axis of the containers relative to the detector, and an activation unit for triggering the detector. The positioning device and a defined coupling area of the container are connectable to one another. The optical detector, without coming into contact, registers items of information on the relative rotational position of a thread portion (2a). The processor device serves to generate data on the rotational position of the container incorporating a defined reference variable and the items of information. The defined reference variable corresponds to a reference point, which is a defined orientation of the container portion and/or a defined marking formed in the beam path of the detector in the area of the positioning device. The defined orientation of the container portion of a support ring and/or a mouth region is a mouth edge extending in a plane. The detector comprises an image pickup unit for detecting the information, a first laser device, which emits a laser beam on the threaded portion for determining the position of the container, and a second laser device for determining the reference value. The collected image information is comparable with the image information stored in a storage unit that reflects rotational positions of the thread. An independent claim is included for a method of optically detecting position of threads of containers.