Packaging Machine Overlapping Area Measurement
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Solution Overview
Problem
Existing packaging machines for liquid food products lack a reliable and automatic method to measure the width of the overlapping area in the packaging material, relying on manual measurements which can be inconsistent and prone to errors.
Innovation Solution
A packaging machine equipped with a control apparatus featuring sensors and imaging devices that utilize reference marks on the packaging material to measure and control the width of the overlapping area, ensuring accurate and automatic detection, and generate warnings for deviations from predefined thresholds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual measurement of overlapping area is used, then device complexity is reduced, but measurement precision and reliability deteriorate
Solution Approach 1:
The patent replaces manual mechanical measurement with an optical imaging system (camera) and automated image processing. The control apparatus captures images of the packaging material and automatically calculates the overlapping area width through digital image analysis, eliminating the need for physical contact measurement tools and manual operations.
Solution Approach 2:
The patent creates a digital copy (image) of the physical overlapping area and performs measurements on this copy rather than the original object. The camera captures an optical copy of the packaging material's overlapping region, and all measurements are derived from analyzing this digital representation, which can be processed repeatedly without affecting the original material.
2Productivity
If manual sampling measurement is used, then device complexity is reduced, but productivity and consistency deteriorate
Solution Approach 1:
The patent enables continuous measurement by integrating the imaging system into the packaging machine's production line. The camera continuously captures images of the packaging material as it moves through the forming process, and the control apparatus continuously processes these images to monitor overlapping area width in real-time, eliminating the interruption caused by periodic manual sampling.
Solution Approach 2:
The measurement system is self-serve in that it automatically performs all measurement operations without human intervention. The control apparatus autonomously captures images, processes them to determine overlapping area width, compares measurements against specifications, and generates warnings or alerts when deviations are detected, freeing operators from manual measurement tasks.
3Reliability
If automated imaging measurement is implemented, then measurement precision and productivity improve, but device complexity increases
Solution Approach 1:
The control apparatus performs multiple functions: it controls the packaging machine's operation, captures images through the integrated camera, processes images to measure overlapping area width, compares measurements against specifications, and generates warnings. This multi-functional integration reduces the need for separate dedicated measurement equipment and simplifies the overall system architecture.
Solution Approach 2:
The camera acts as an intermediary between the physical packaging material and the control system. It converts optical information from the overlapping area into electrical signals (images) that the control apparatus can process digitally. This intermediary enables reliable automated measurement by bridging the gap between physical dimensions and digital analysis.
Data Source
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AI summary
A packaging machine and method for producing sealed packages from a packaging material fed along a conveying path (P) and having a plurality of patterns (12) of reference marks comprising at least two reference marks (14, 15; 14*, 15*), said machine comprises a control apparatus (8) with a sensing device (17) configured for measuring at least a first parameter (D1; V) of the packaging material unit when the packaging material has a planar shape, an imaging device (9) configured for measuring at least a second parameter (D2 ; D4) of the packaging material when the packaging material has a substantially tubular shape, and a control unit (16) connected to both the sensing device (17) and the imaging device (11) and configured for calculating the width of an overlapping area (AO) of the tube (5) based on said first parameter (D1; V) and said second parameter (D2; D4) .