Packaging Machine Inspection with Selective Planar Motor Routing

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Solution Overview

Problem

Existing packaging machines for pourable products lack an efficient and cost-effective means to inspect and control the quality of packages during production, often requiring manual intervention for quality control sampling.

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 to selectively inspect packages for quality and defects, allowing for automated quality control without interrupting production.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If automated inspection apparatus is implemented, then quality control capability is improved, but device complexity increases

Engineering Contradiction:

Improvequality control capabilityVSAvoiddevice complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The inspection apparatus is divided into multiple independent inspection units, each equipped with specialized sensors (optical, acoustic, weight, dimensional) that can be selectively activated based on inspection needs, reducing overall system complexity while maintaining comprehensive quality control capability

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The control unit serves multiple functions: it coordinates the conveying device, manages multiple inspection units with different sensor types, determines quality based on various measurement criteria, and controls package routing. This multi-functionality consolidates what could be multiple separate systems into a single integrated apparatus

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Productivity

If automated inspection is implemented, then productivity is improved, but device complexity increases

Engineering Contradiction:

Improveproduction efficiencyVSAvoiddevice complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The conveying device continuously transports packages through the inspection apparatus without interruption, while inspection units perform measurements during transit. This continuous operation maintains high productivity while the modular inspection units can be selectively activated to minimize complexity

Inventive Principle:

Principle #20Continuity of useful action

Solution Approach 2:

Traditional manual quality control operations are replaced with automated sensors and control systems that perform measurements and routing decisions automatically, improving productivity while the modular architecture prevents excessive complexity increase

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Manufacturing precision

If comprehensive quality inspection is performed, then manufacturing precision is improved, but measurement precision requirements increase

Engineering Contradiction:

Improvequality inspection accuracyVSAvoidmeasurement precision

Core Design Contradiction:

Manufacturing precisionVSMeasurement precision

Solution Approach 1:

Different inspection units are equipped with specialized sensors matched to specific quality attributes (optical sensors for visual defects, acoustic sensors for seal integrity, weight sensors for fill accuracy, dimensional sensors for package dimensions). This localized specialization achieves comprehensive manufacturing precision without requiring every sensor to achieve ultra-high precision across all measurement types

Inventive Principle:

Principle #3Local quality

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

Enables automated, high-speed quality inspection and control of packages, improving production efficiency and reducing the need for manual sampling while maintaining production speed and quality standards.

Implementation Method 1

conveying device (7) configured to move packages (2) along a conveying path

Methodology Applied

Scientific EffectMechanical force: Mechanical Force

Implementation Method 2

inspection units (8) configured to inspect packages (2) at inspection stations (14)

Methodology Applied

Scientific EffectLight detection: Light

Data Source

PatentUS20250313419A1Inspection apparatus for a packaging machine and packaging machine having an inspection apparatus

Publication Date: 2025.10.09 TETRA LAVAL HOLDINGS & FINANCE SA

AI summary

There is described an inspection apparatus for a packaging machine producing packages and comprising a control unit for controlling the inspection apparatus, a conveying device and an inspection unit configured to inspect packages. The conveying device comprises a planar motor having a plurality of carriers configured to receive respective packages at an inlet station and to deliver the respective packages to an outlet station. The inspection unit is arranged adjacent to the planar motor at an inspection station. The control unit is configured to selectively control movement of the carriers so as to selectively direct one or more carriers to the inspection station and afterwards to the outlet station and the inspection unit is configured to inspect the packages moved, in use, to the inspection station.