Packaging Machine Consumable Quality Control via Sensor Detection
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Solution Overview
Problem
Packaging machines often encounter malfunctions due to consumables that do not meet specified quality criteria, making it difficult to trace the cause of issues and leading to inefficiencies and quality control challenges.
Innovation Solution
A device with a sensor system that detects physical properties of consumables, compares them to setpoint values, and outputs signals for deviations, allowing for real-time quality control, marking of defective materials, and potential ejection, thereby ensuring only compliant materials are used.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If consumables are inspected only after application, then the inspection process is simple, but machine malfunctions occur and quality control is compromised
Solution Approach 1:
The sensor device inspects consumables during the transport phase, before they reach the application unit. This preliminary inspection allows defective consumables to be identified and rejected before they can cause machine malfunctions or quality issues, resolving the contradiction by moving the inspection action to an earlier time point in the process
2Measurement precision
If multiple sensor devices are added for comprehensive quality control, then detection accuracy improves, but device complexity increases
Solution Approach 1:
The quality control function is segmented into multiple independent sensor devices, each detecting specific properties of the consumable (e.g., presence, position, physical properties). This segmentation allows comprehensive quality detection while maintaining modularity, making the system easier to implement and maintain compared to a single complex inspection system
3Reliability
If real-time quality control is implemented, then machine reliability improves, but the device complexity increases due to additional sensor and comparison devices
Solution Approach 1:
The comparison device continuously compares actual values from sensor devices with target values and provides feedback signals when deviations are detected. This feedback mechanism enables real-time quality control and automatic rejection of defective consumables, improving machine reliability while using a relatively simple control logic that avoids excessive complexity
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
Enhances failsafety and efficiency by allowing for immediate detection and response to substandard consumables, reducing machine malfunctions and quality costs, and enabling precise logging of consumable-related errors for improved supplier accountability.
Implementation Method 1
at least one sensor device (12, 14, 16) which detects at least one actual value (I1, I2, I3) of the consumable (20) that is characteristic of a physical property of the consumable (20)
Data Source
Figure 1~2
AI summary
The invention relates to a device (1) for applying consumable materials (20) to containers (10), comprising a storing apparatus (2) that stores a supply of the consumable material (20), a transporting apparatus (4) that conveys the consumable material (20) to the containers (10), and an application unit (6) that applies the consumable material (20) to the containers (10) or to combinations (40) of containers (10). According to the invention, the device (1) has at least one sensor apparatus (12, 14, 16), which detects at least one actual value (I1, I2, I3) of the consumable material (20) that is characteristic of a physical property of the consumable material (20), a comparing apparatus (35), which compares the detected actual value (I1, I2, I3) with at least one target value (S1, S2, S3) stored in a memory apparatus (32), and a signal outputting apparatus (34), which outputs a signal according to a result of said comparison.