Polarized Light Container Stability Testing
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Solution Overview
Problem
Existing filling systems face challenges in detecting unstable containers that may burst during the filling process, leading to productivity losses, machine damage, and potential contamination risks, as current methods do not effectively identify containers with structural defects or wear that compromise pressure and temperature resistance.
Innovation Solution
A testing system that uses polarized test light and a change-based test camera to analyze the polarization direction of light passing through containers, detecting structural anomalies by local changes in brightness, and characterizes container stability through a testing algorithm, incorporating stress exposure and machine learning for improved detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional inspection devices are used to detect visible damage, then obvious defects can be identified, but unstable containers with structural defects that lack pressure resistance cannot be detected
Solution Approach 1:
The system performs preliminary testing on containers before they enter the filling process. A test filling device introduces a test medium into containers to be tested, and a testing camera captures images of the containers under test conditions. This preliminary detection identifies unstable containers before they reach the main filling device, preventing potential bursts during actual filling operations.
Solution Approach 2:
A test medium is introduced as an intermediary substance to apply pressure to containers during testing. The test medium fills containers to a predetermined pressure level, allowing the testing system to detect structural weaknesses without requiring the full production filling process. This intermediary testing step enables safe identification of unstable containers.
2Productivity
If containers are pressurized during pre-pressurization and filling to increase throughput, then productivity improves, but unstable containers may burst causing machine damage and contamination
Solution Approach 1:
The system performs preliminary stability testing on all containers before they enter the high-speed filling process. By identifying and removing unstable containers in advance, the system enables safe pressurization during actual filling operations without risking bursts, thus maintaining high productivity while eliminating the burst hazard.
Solution Approach 2:
The testing system provides feedback to the control unit about which containers are stable and which are unstable. The control unit uses this feedback information to control the filling device, allowing it to proceed with high-speed filling of stable containers while diverting or rejecting unstable containers, thereby maintaining both productivity and safety.
3Object-affected harmful factors
If a damage detection system diverts containers near a rupture to ensure safety, then consumer protection improves, but up to 20 or more containers are discarded causing productivity loss
Solution Approach 1:
The system performs preliminary identification of unstable containers before the filling process begins. By sorting out problematic containers in advance, the system prevents the need for extensive diversion and discarding of containers after a rupture event, thereby maintaining both safety and productivity throughout the filling operation.
Solution Approach 2:
Each container is individually tested and self-identified as stable or unstable through the testing system. This eliminates the need for blanket diversion of multiple containers following a rupture, as only the specific unstable containers that were identified in advance need to be rejected, not healthy containers near them.
4Measurement precision
If manual inspection or basic automated systems are used to identify defective containers, then device complexity remains low, but detection precision for structural defects and wear is insufficient
Solution Approach 1:
The system replaces manual inspection or simple automated mechanical detection with an optical-based testing system. A testing camera captures images of containers under pressure, and an evaluation unit with image processing algorithms analyzes these images to detect structural defects, cracks, and wear. This substitution of mechanical inspection with optical detection and computational analysis achieves high detection precision while maintaining manageable system complexity.
Solution Approach 2:
The system changes the parameter being measured from simple visual appearance to structural integrity under pressure. By introducing a test medium to pressurize containers and capturing images under these controlled conditions, the system detects subtle structural defects and wear that are invisible under normal conditions, significantly improving detection accuracy.
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
Preventively reduces the likelihood of container bursts by accurately identifying unstable containers, minimizing downtime and contamination risks, and optimizing the filling process by modifying the handling of potentially unstable containers.
Implementation Method 1
The testing device is configured to illuminate or pass through the container to be tested with polarized test light and to analyze or filter the reflected or transmitted test light with respect to its polarization direction
Implementation Method 2
A testing device for testing transparent containers, in which crossed polarizers are used
Data Source
Figure 1
AI summary
The invention relates to a method for testing containers to be filled and identifying unstable containers in a filling plant, comprising the following test steps: - illuminating a container to be tested with polarized test light; - detecting the test light reflected or transmitted by the container to be tested using a change-based test camera, which has an image sensor configured to generate output signals exclusively in response to detected changes in brightness, wherein the test camera is associated with a polarizer which is oriented such that the polarization direction of the light passing through the polarizer differs from the polarization direction of the test light generated by the illumination device; - checking the output signals generated by the test camera for the presence of local changes in brightness.Determining a measure of the structural integrity of the container under test, at least based on a detected local change in brightness and predefined test criteria, and characterizing the container under test with regard to its stability, at least based on the determined measure of structural integrity, using a test algorithm and generating a container stability signal based thereon. The invention further relates to a corresponding test system and a filling system with such a test system.