Robotic Gas Detector for Package Leak Detection
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Solution Overview
Problem
Current leak detection methods for packages, particularly for food products, are time-consuming and inefficient, often requiring manual testing and unable to locate leaks accurately, limiting the throughput and quality control in food packaging production.
Innovation Solution
A method utilizing a robot arm with a gas detector and marker to automatically detect and mark leaks in packages, allowing for efficient and precise identification of leaks along a predetermined detection path, with the option to use multiple detectors and tracers like helium or carbon dioxide, and adapt to different package materials and shapes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual pressure testing with water is used, then leak detection is simple and direct, but the process is time-consuming and cannot locate leaks precisely
Solution Approach 1:
The patent replaces manual mechanical pressure testing with an automated robotic system equipped with gas detectors. The robot arm moves along detection paths and uses sensor-based detection (mass spectrometry or other gas sensing technologies) to identify leaks, eliminating the need for manual water pressure testing and significantly increasing throughput while maintaining detection accuracy.
Solution Approach 2:
The system employs automated robotic detection that operates independently without manual intervention. The robot arm autonomously navigates detection paths, and the gas detectors automatically identify leaks based on tracer gas concentration measurements, enabling continuous operation and eliminating time losses associated with manual testing procedures.
2Measurement precision
If tracer gas detection is used, then leak location is possible, but the process requires waiting for tracer gas dissipation between tests
Solution Approach 1:
The patent implements periodic scanning of packages along the production line using the robotic detection system. Instead of requiring complete dissipation of tracer gas between tests, the system performs rapid sequential measurements at different locations and times, identifying leaks through temporal and spatial patterns in the gas concentration data.
Solution Approach 2:
The robotic detection system operates continuously along the production line without interruption to the packaging process. Multiple gas detectors on the robot arm can simultaneously monitor different sections of packages, and the system continuously scans for leaks without requiring stops for tracer gas dissipation, maintaining continuous productive action.
3Quantity of substance
If carbon dioxide is used as tracer gas, then smaller molecules are used, but smallest leaks cannot be detected reliably
Solution Approach 1:
The patent employs mass spectrometry or other highly sensitive gas detection technologies that can detect trace concentrations of various gases including helium, hydrogen, and carbon dioxide. By changing the detection parameter to ultra-sensitive mass-based or concentration-based sensing, the system can reliably detect the smallest leaks regardless of the tracer gas molecule size, achieving both small molecule usage and high detection sensitivity.
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
This approach significantly increases the efficiency of leak detection, enabling higher throughput and accurate location of leaks, thereby improving the quality of food products and reducing production costs by automating the process and allowing for continuous operation of the production line.
Implementation Method 1
at least one leak detector having a robot arm with at least one gas detector
Implementation Method 2
the robot arm further comprises a marker for marking a location of a leak on a leaky package
Data Source
Figure 1~2
AI summary
Method for detecting leaks in packages (4) processed in a production line (11) comprising at least one leak detector (1) having a robot arm (2) with at least one gas detector (3), the method comprising at least the following steps: moving the gas detector (3) along a detection path covering at least a part of at least one of the packages (4), and deciding if a package (4) is deemed to be leaky based on the data gathered by the gas detector (3). A method is provided for detecting leaks in packages (4) for food products that are filled with an inert gas and a tracer gas such as helium. The tracer gas can be detected by a gas detector (1) moved along the package by a robot arm (2). Compared with methods for a stationary gas detector, this method provides an improved efficiency because a dissipating of the tracer gas between test cycles does not have to be awaited.