Plastics Preform Image Inspection for Real-Time Container Production
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Solution Overview
Problem
Existing systems for producing plastics material containers require more precise monitoring of preforms to reduce errors and waste, but current methods lack effective automation and timely adjustment of process parameters based on real-time inspection results.
Innovation Solution
An apparatus and method that integrates a production device, forming device, transport apparatus, and inspection devices with control systems to monitor and adjust production and forming processes in real-time, using spatially resolved imaging and evaluation of preforms to optimize parameters and sort or reject defective items.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by stationary object
If preforms are produced by injection molding machines and then formed, then less heating of preforms is required, but more precise monitoring of preforms is needed to reduce errors and waste
Solution Approach 1:
The system performs preliminary inspection of preforms using image recording devices before they enter the forming process. This allows defects to be detected early, enabling preventive actions such as adjusting injection parameters or rejecting defective preforms before they consume additional heating energy during forming.
Solution Approach 2:
The inspection system provides real-time feedback on preform quality to the control device. This feedback loop enables dynamic adjustment of production parameters and immediate identification of quality issues, reducing waste by preventing defective preforms from proceeding through the energy-consuming heating and forming processes.
2Productivity
If a plurality of production units and forming stations are used, then productivity increases, but coordination and synchronization between units becomes more complex
Solution Approach 1:
The control device serves multiple functions simultaneously: it coordinates production units, manages forming stations, operates transport apparatus, and processes inspection data. This multi-functionality reduces the need for separate control systems for each component, simplifying overall system coordination while maintaining high productivity.
Solution Approach 2:
The system merges the control functions of production, forming, transport, and inspection into a single integrated control device. This consolidation synchronizes all operations seamlessly, allowing multiple production units and forming stations to work in coordinated harmony without requiring complex inter-system communication protocols.
3Reliability
If inspection devices are integrated between production and forming, then error detection improves, but system complexity increases
Solution Approach 1:
The inspection system is merged with the existing production and forming equipment, sharing common infrastructure such as the transport apparatus and control device. This integration approach improves error detection capability without proportionally increasing system complexity, as the inspection devices utilize existing system components rather than requiring entirely separate systems.
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 automation, reduces errors and waste by allowing precise control and sorting of preforms, improving the quality and efficiency of plastics material container production.
Implementation Method 1
the first inspection device has an image recording device that is suitable and intended for recording at least one spatially resolved image of a plurality of plastics material preforms
Data Source
AI summary
An apparatus for producing plastics material containers has a production device having a plurality of production units, a forming device having a plurality of forming stations, a transport apparatus that is configured for transporting the plastics material preforms produced by the production device to the forming device, and a cooling device for cooling the plastics material preforms produced by the production device. An inspection device that is configured for inspecting at least one region of the plastics material preforms produced by the production device, is arranged between the production device and the cooling device, and has an image recording device that is configured for recording a spatially resolved image of a plurality of plastics material preforms.