Sensor Bottle Monitoring for Predictive Bottling Line Control
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Solution Overview
Problem
Current bottling systems are complex and costly, requiring minimal downtime and frequent maintenance, and lack effective solutions for real-time monitoring and optimization of bottling line performance.
Innovation Solution
A bottle equipped with sensors and a battery, capable of collecting and transmitting data on various parameters such as temperature, pressure, and chemical concentrations, integrated with a network for predictive analytics and automated controls to optimize bottling line operations and predict equipment failures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If complex and costly bottling systems are used to fill a large number of bottles, then productivity is improved, but device complexity and cost increase
Solution Approach 1:
The bottle itself serves as the sensing device by incorporating sensors directly into its structure. The bottle's sensors autonomously monitor parameters such as filling volume, capping torque, and transport conditions without requiring external inspection systems, enabling the product to self-diagnose and self-report its processing status throughout the bottling line.
Solution Approach 2:
The sensor bottle serves multiple functions simultaneously: it contains the beverage, monitors processing parameters (filling, capping, labeling), tracks its own position and orientation, and communicates data to the control system. This multi-functionality eliminates the need for separate inspection devices for each parameter, reducing overall system complexity while maintaining high productivity.
2Measurement precision
If numerous inspection systems with cameras and sensors are installed along the bottling line, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The inspection function is extracted from the bottling line infrastructure and transferred to the bottle itself. Instead of installing external cameras and sensors to monitor each bottle, the sensing capability is embedded within the bottle, allowing precise measurement of filling volume, capping torque, and other parameters without adding complex external inspection equipment.
Solution Approach 2:
The sensor bottle acts as an intermediary between the bottling process and the control system. Rather than requiring direct line-of-sight inspection from external cameras, the bottle's embedded sensors directly measure process parameters and transmit data wirelessly, simplifying the measurement architecture while maintaining high precision.
3Manufacturing precision
If stand-alone inspection systems with push rejection devices are used, then manufacturing precision is maintained, but device complexity and space requirements increase
Solution Approach 1:
The sensor bottle provides real-time feedback on processing quality by continuously monitoring parameters such as fill volume, cap tightness, and label application. This feedback is transmitted to the control system, which can immediately adjust process parameters or flag defective bottles, maintaining manufacturing precision without requiring complex stand-alone inspection and rejection systems.
Data Source
AI summary
System and method for optimizing bottling line performance based on data received from a bottle with sensors. The system provides a bottle with sensors in a bottling line or maintenance system, a network gateway, a human machine interface (HMI) device, and a platform server. The HMI device provides for local control of the bottling line while the platform server handles distribution of GUIs, as well as data processing, data storage, and data analysis.