Planar Motor Package Inspection for High-Speed Quality Control
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Solution Overview
Problem
Existing packaging machines lack efficient and cost-effective means for inspecting and controlling the quality of packages produced at high speeds, often requiring manual intervention for quality control.
Innovation Solution
An inspection apparatus integrated into the packaging machine that includes a control unit, conveying device, and inspection units with imaging and scanning capabilities, allowing for selective inspection and quality control of packages without interrupting production, using carriers with six degrees of freedom for precise positioning and weight detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual sampling inspection is used for quality control, then operator intervention can detect defects, but production speed is reduced and labor costs increase
Solution Approach 1:
The patent replaces manual mechanical inspection with an automated optical inspection system using cameras and image processing algorithms. The system captures images of packages during production and automatically analyzes them for defects, eliminating the need for manual sampling while maintaining inspection accuracy and preserving production speed.
Solution Approach 2:
The inspection system performs self-inspection by automatically capturing, processing, and analyzing package images without human intervention. The control unit autonomously evaluates package quality based on image data, enabling the system to inspect packages at full production speed without requiring operator sampling.
2Productivity
If automated inspection systems are implemented, then production speed is maintained, but system complexity and cost increase
Solution Approach 1:
The inspection system is designed to perform multiple inspection functions using a single integrated platform. The same camera system and control unit can inspect different package types and detect various defect types, reducing the need for multiple specialized inspection devices and simplifying the overall system architecture.
Solution Approach 2:
The system uses optical copying (imaging) to create digital representations of packages for inspection. By capturing images and analyzing them computationally, the system avoids complex physical measurement devices and enables sophisticated inspection through software processing of visual copies.
3Measurement precision
If comprehensive quality inspection is performed on all packages, then defect detection is maximized, but inspection time and production throughput are reduced
Solution Approach 1:
The inspection system operates continuously alongside the production line, inspecting packages in real-time as they move through the manufacturing process. This eliminates the need for separate inspection stages or production stoppages, allowing comprehensive inspection without reducing overall production throughput.
Solution Approach 2:
The system performs rapid image capture and processing, quickly analyzing packages as they pass by. The high-speed imaging and automated image processing enable comprehensive inspection to be completed in the brief moment packages are visible on the conveyor, preventing any bottleneck in production flow.
Data Source
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AI summary
There is described an inspection apparatus (5) for a packaging machine (1) producing packages (2) and comprising a control unit (6) for controlling the inspection apparatus (5), a conveying device (7) and an inspection unit (8) configured to inspect packages (2). The conveying device (7) comprises a planar motor (10) having a plurality of carriers (11) configured to receive respective packages (2) at an inlet station (12) and to deliver the respective packages (2) to an outlet station (13). The inspection unit (8) is arranged adjacent to the planar motor (10) at an inspection station (14). The control unit (6) is configured to selectively control movement of the carriers (11) so as to selectively direct one or more carriers (11) to the inspection station (14) and afterwards to the outlet station (14) and the inspection unit (8) is configured to inspect the packages (2) moved, in use, to the inspection station (14).