Preform Heating Ramp Positioning Using Image-Based Diameter Detection
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Solution Overview
Problem
Existing methods for adjusting the spacing of protective ramps in preform heating stations during format changes are time-consuming and prone to human error, leading to suboptimal spacing that can cause heat transfer issues or preform jamming.
Innovation Solution
A method involving an image capturing device to automatically determine the under-neck diameter and neck height of preforms, using motorized devices to adjust the width and height of ramps, controlled by an electronic control unit, ensuring precise positioning of ramps based on actual preform dimensions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual adjustment of ramp spacing is used during format changes, then device complexity is reduced, but adjustment time increases and positioning precision deteriorates
Solution Approach 1:
The patent replaces manual mechanical adjustment with an automated system comprising an image capturing device, electronic control unit, and motorized positioning mechanisms. The system captures images of preforms, processes the images to determine dimensions, and automatically positions ramps accordingly, eliminating manual intervention and significantly reducing adjustment time while improving positioning precision.
Solution Approach 2:
The system enables self-service by automatically measuring preform dimensions through image capture and processing, then autonomously adjusting ramp positions without human intervention. The electronic control unit receives image data, calculates appropriate ramp spacing, and controls motorized devices to position ramps, creating a self-regulating adjustment process.
2Manufacturing precision
If manual adjustment of ramp spacing is used, then device complexity is reduced, but adjustment accuracy deteriorates due to human error
Solution Approach 1:
The patent replaces error-prone manual measurement and judgment with an automated optical measurement system. The image capturing device objectively records preform dimensions, and the electronic control unit processes this data to determine precise ramp spacing, eliminating human error while the added complexity is justified by the significant improvement in accuracy.
Solution Approach 2:
The system creates a digital copy of the preform through image capture, then processes this copy to extract dimensional information. This digital replica allows for precise measurement and calculation without physically contacting the preform, enabling accurate determination of ramp spacing based on actual preform geometry rather than theoretical values.
3Reliability
If incorrect ramp spacing is used, then device complexity is reduced, but preform damage risk increases due to jamming or heat transfer
Solution Approach 1:
The system implements feedback by capturing images of actual preforms, processing these images to determine real dimensions, and using this information to adjust ramp positioning. This closed-loop approach ensures ramp spacing is continuously optimized based on actual preform geometry, preventing both jamming (from too narrow spacing) and heat transfer (from too wide spacing), thereby improving reliability.
Solution Approach 2:
The system performs preliminary measurement and positioning before preforms are processed. By capturing images and determining appropriate ramp spacing in advance, the system pre-configures the optimal positioning to prevent damage during subsequent processing, rather than reacting to problems after they occur.
Data Source
AI summary
Provided are methods for automatically positioning ramps in a station for the heating of preforms. The method includes acquiring an image of a preform traveling along a slot delimited by a pair of ramps, where at least one of the ramps is transversely mobile to vary the width of the slot (56) and where a motorized device transversely moves the at least one mobile ramp and is controlled automatically by an electronic control unit. The method further includes automatically determining the diameter below the neck of the preform by computer processing the image and automatically adjusting the width of the slot by moving the at least one mobile ramp according to the determined diameter below the neck.