Packaging Machine Rotor Foreign Object Detection
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Solution Overview
Problem
Existing packaging machines have insufficient accuracy in detecting foreign objects during the sealing and cutting processes, as they rely on threshold comparisons or disturbance observers that do not effectively identify machine operation anomalies.
Innovation Solution
A control apparatus and system that utilize a rotor with heaters and cutters to seal and cut packaging material, incorporating an information obtaining unit and a determination unit to analyze status values of the driver, calculating correlation coefficients and characteristic values to accurately detect abnormalities, such as foreign object bites, by monitoring rotational positions and speed deviations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If threshold comparison or disturbance observer methods are used for detecting foreign objects, then the device complexity is reduced, but the measurement precision and reliability of detection are insufficient
Solution Approach 1:
The patent replaces traditional mechanical detection methods (sensors, switches) with a motor control-based detection system. The control unit analyzes operational data (current, speed, acceleration) from the existing motor driver to detect foreign objects, eliminating the need for separate detection sensors and achieving high precision without increasing device complexity
Solution Approach 2:
The motor driver's operational data, which is already being collected for control purposes, is repurposed for foreign object detection. The system uses its own operational parameters (current consumption, speed deviations, acceleration patterns) to detect abnormalities, making the detection system self-service and avoiding additional sensors
2Reliability
If simple threshold comparison is used, then the ease of operation is improved, but the reliability of detection is insufficient
Solution Approach 1:
The control unit continuously monitors motor operational data and compares it against reference values to provide feedback on foreign object detection. The system uses feedback from current consumption patterns, speed deviations, and acceleration changes to reliably detect foreign objects while maintaining automated operation that is simple to implement
Solution Approach 2:
The system performs preliminary detection by analyzing motor operational data before the packaging process completes. The control unit continuously evaluates current, speed, and acceleration data during motor operation to identify foreign objects early, enabling timely intervention while maintaining simple automated operation
3Measurement precision
If disturbance observer with torque command and motor speed is used, then the measurement precision is improved, but the device complexity increases
Solution Approach 1:
The control unit performs multiple functions using the same operational data: motor control, sealing/cutting process control, and foreign object detection. By making the control system universal and using existing operational data for multiple purposes, the patent achieves high detection precision without increasing device complexity
Solution Approach 2:
The patent merges the foreign object detection function with the existing motor control system. The control unit combines analysis of current, speed, and acceleration data that are already being collected for motor control purposes, integrating detection functionality into the existing control architecture to avoid increasing system 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
The system achieves more accurate detection of foreign object bites and sealing defects, enhancing the reliability and precision of packaging processes.
Implementation Method 1
The rotor includes at least one heater on an outer circumferential surface thereof. The heater seals the packaging material.
Implementation Method 2
The rotor includes a cutter on an outer circumferential surface thereof. The cutter cuts the packaging material.
Data Source
AI summary
A method accurately detects biting of a foreign object in a packaging machine. A control apparatus controls a packaging machine that sequentially seals and/or cuts a packaging material transported in a first direction using a rotor. The rotor is arranged to have a tangent to its outer circumference portion in contact with the packaging material extending in the first direction. The rotor is drivable and rotatable by a driver. The control apparatus includes an information obtaining unit that obtains information indicating a rotational position of the rotor and a status value of the driver in predetermined cycles, and a determination unit that determines a presence of an abnormality in a sealed portion of the packaging material using, from the information obtained by the information obtaining unit, a status value of the driver corresponding to a rotational position of the rotor falling within a predetermined range or being a predetermined position.