Orthogonal Camera Tray Measurement for Packaging Film Wrapping
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Solution Overview
Problem
Existing packaging machines face challenges in accurately determining the dimensions of packaging trays, leading to inefficient film wrapping due to manual input errors and the inability to adapt to different tray types, resulting in suboptimal wrapping speed, film length, and tension.
Innovation Solution
An object measurement system using two cameras to capture orthogonal views of the packaging tray, allowing for precise determination of the base area and height, which are then used to control the folding tongs, film cutting, and holding mechanism adjustments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual input of tray dimensions is used, then the packaging machine can operate with simple control, but measurement precision and reliability deteriorate due to operator errors and input mistakes
Solution Approach 1:
The system uses automated optical measurement to allow the packaging machine to self-determine tray dimensions without manual operator intervention. The measurement device automatically captures images and calculates dimensions, enabling the system to serve itself rather than relying on human input that is prone to errors.
Solution Approach 2:
The patent replaces manual mechanical input methods with an automated optical measurement system using cameras and image processing. This substitution eliminates the need for operators to manually enter tray dimensions, replacing human operation with an automated technical system that provides more reliable and precise measurements.
2Device complexity
If the packaging machine uses fixed wrapping parameters, then the device complexity is reduced, but adaptability deteriorates when different tray types are processed
Solution Approach 1:
The system dynamically adjusts wrapping parameters such as folding jaw positions, film cutting length, and holding element distance based on the measured tray dimensions. This dynamic adaptation allows the packaging machine to automatically adjust to different tray types without increasing physical complexity, as the adjustments are made through controlled parameter changes rather than mechanical reconfiguration.
Solution Approach 2:
The patent implements automatic parameter adjustment where the control unit modifies wrapping settings based on measured tray dimensions. By changing parameters like folding jaw position, film length, and holding mechanism distance according to actual tray measurements, the system achieves high adaptability while maintaining relatively simple device architecture.
3Reliability
If the distance between holding elements is reduced for high trays, then film sagging is prevented, but the manufacturing precision of the holding mechanism must be high
Solution Approach 1:
The holding element distance is dynamically adjusted based on the measured tray height rather than using a fixed position. The control unit automatically sets the optimal distance between holding elements for each tray type, ensuring reliable film tensioning while allowing flexibility to accommodate different tray dimensions without requiring extremely tight manufacturing tolerances on the holding mechanism itself.
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 reliable differentiation of trays with varying dimensions, ensuring optimal wrapping speed, film length, and tension, improving the packaging process by eliminating manual input errors and adapting to different tray types.
Implementation Method 1
a first camera (21) arranged opposite the first boundary surface (31), which is designed to generate an image of a top view, in particular as a color image
Implementation Method 2
a second camera (22) arranged opposite the second boundary surface (32), which is designed to generate an image of a side view, in particular as a color image
Implementation Method 3
an evaluation unit (16) connected to the cameras (21, 22) for evaluating the images of the packaging tray recorded by the cameras
Data Source
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AI summary
The present invention relates to an object measurement system for a packaging machine, which is configured for wrapping packaging trays with film, for determining the dimensions of a base and a height of a packaging tray to be wrapped. The object measurement system comprises a receiving chamber for the packaging tray, a first and a second camera for capturing electronic images, in particular color images, of a respective packaging tray arranged in the receiving chamber, wherein the first and the second camera are arranged relative to each other and in relation to the receiving chamber such that the detection directions of the two cameras are transverse, in particular orthogonal, to each other, and that the first camera captures a top view of the packaging tray and the second camera a side view of the packaging tray, and an evaluation device connected to the cameras for evaluating the images of the packaging tray captured by the cameras.wherein the evaluation device is configured to determine a base contour of the detected packaging tray in a color image of the top view, to determine a color value for the area bounded by the base contour in the color image of the top view, to select, based on the determined color value, an image area in the color image of the side view corresponding to the side surface of the detected packaging tray which has a color value corresponding to the determined color value, to determine the height of the detected packaging tray based on the selected image area corresponding to the side surface, and to determine the dimensions of the base of the detected packaging tray based on the determined base contour.