Packaging Machine Camera Drift Detection Using Reference Marks

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Solution Overview

Problem

Existing vision-based monitoring systems in packaging machines are prone to inaccuracies due to food product residues obstructing the camera's field of view, leading to deteriorating image data quality over time, which can result in incorrect conclusions and machine malfunctions.

Innovation Solution

Implement reference marks on packaging material, such as barcodes, to serve dual purposes of identification and image quality assessment, allowing for the detection of image data quality drift by comparing common features across different time points, and triggering cleaning mechanisms when deterioration criteria are met.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If vision-based monitoring systems are used for quality inspection and barcode reading in packaging machines, then package quality assessment and traceability are improved, but image data quality deteriorates over time due to food product residues obstructing the camera field of view

Engineering Contradiction:

Improvequality inspection accuracyVSAvoidimage data quality

Core Design Contradiction:

ReliabilityVSMeasurement precision

Solution Approach 1:

The system captures image data of reference marks at multiple time points, compares the visual representation of common features across these images, and uses the detected drift as feedback to determine when cleaning is required. This closed-loop feedback mechanism continuously monitors image quality and triggers maintenance actions based on actual degradation levels.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

Reference marks are introduced as intermediary elements that serve dual purposes: they enable quality inspection functions while simultaneously acting as indicators for image quality assessment. The reference marks mediate between the camera system and the packaging material, providing a stable reference for detecting both package features and image degradation.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Productivity

If the camera operates continuously without cleaning, then productivity is maintained, but incorrect conclusions may be made due to deteriorating image data quality

Engineering Contradiction:

Improvemachine uptimeVSAvoidconclusion accuracy

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

Instead of implementing continuous cleaning operations, the system performs partial cleaning actions only when necessary. By monitoring image quality drift and triggering cleaning only when deterioration criteria are met, the system avoids excessive cleaning interruptions while still maintaining sufficient image quality for accurate conclusions.

Inventive Principle:

Principle #16Partial or excessive action

Solution Approach 2:

The vision system performs self-diagnosis by automatically assessing its own image data quality through reference mark analysis. The system monitors its own performance degradation and autonomously determines when maintenance is required, enabling self-service operation without continuous external intervention.

Inventive Principle:

Principle #25Self-service

3Loss of information

If reference marks are added to packaging material for identification purposes, then package tracking capability is improved, but device complexity increases

Engineering Contradiction:

Improvepackage traceabilityVSAvoidsystem complexity

Core Design Contradiction:

Loss of informationVSDevice complexity

Solution Approach 1:

Reference marks are designed to serve multiple functions simultaneously: they enable package identification and tracking while also providing a basis for image quality assessment. This multi-functionality eliminates the need for separate reference objects, reducing overall system complexity despite the added functionality.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The system merges the quality inspection function with the image quality monitoring function by using the same reference marks for both purposes. This consolidation combines what could be separate systems into a unified approach, reducing complexity rather than increasing it.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentEP4668209A1A method and apparatus for supporting an operation of a packaging machine

Publication Date: 2025.12.24 TETRA LAVAL HOLDINGS & FINANCE SA

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AI summary

A computer-implemented method (600) for supporting operation of a packaging machine (100), wherein the packaging machine (100) comprises a camera (120) and a packaging material receiver (118) arranged to receive a packaging material, said method comprising capturing (602) a first set (SET-1) of image data using the camera (120) at a first point of time (T-1), wherein the first set of image data depicts a first reference mark (REF-1) provided on a first piece (P-1) of the packaging material, capturing (604) a second set (SET-2) of image data using the camera (120) at a second point of time (T-2), wherein the second set of image data depicts a second reference mark (REF-2) provided on a second piece (P-2) of the packaging material, determining (606) a measure associated to a common feature of the first and second reference marks (REF-1, REF-2), identifying (608) a drift of a visual representation of the common feature based on the measure, and transmitting (610) a visual representation deterioration indication in case the drift fulfills a deterioration criteria.