Sensor-Based Defect Detection in Smokeless Tobacco Portion Packet Sealing
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Solution Overview
Problem
Existing devices for packaging smokeless tobacco or non-tobacco snuff products lack effective methods for identifying and rejecting defective portion packets beyond weight and size issues, such as incomplete sealing, improper positioning, and product material outside the packaging.
Innovation Solution
A device equipped with a sensor member that generates data on portion packets, comparing it to reference data to identify defects, and a control system that controls a rejection system to remove defective packets, using various radiation types and vision sensors to assess packaging quality and position.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If weight-based detection is used to identify defective pouches, then pouches with incorrect fill amount can be rejected, but other defects such as incomplete sealing, improper positioning, and product material outside packaging cannot be detected
Solution Approach 1:
The sensor member is configured to detect multiple types of defects including incomplete sealing, improper positioning, and product material outside packaging, in addition to weight measurement. This multi-functional detection capability allows a single device to identify various defect types that were previously undetectable by weight-based methods alone
Solution Approach 2:
The patent replaces manual inspection with an automated sensor member that uses optical or other non-contact detection methods to identify defects. The sensor member generates information about pouch positioning, sealing completeness, and material containment without physical contact, substituting mechanical/visual inspection with automated sensing
2Reliability
If manual inspection is used to identify defective pouches, then various defects can be detected, but production efficiency is reduced and quality consistency is compromised
Solution Approach 1:
The sensor member and control system automatically detect and identify defective pouches without human intervention. The system self-regulates by generating defect information and triggering rejection mechanisms, eliminating the need for manual quality control while maintaining consistent detection standards
Solution Approach 2:
The sensor member continuously monitors pouch characteristics and provides real-time feedback to the control system. This feedback loop enables immediate identification and rejection of defective pouches, ensuring quality consistency while maintaining high production speeds through automated closed-loop control
3Extent of automation
If automated rejection system is implemented, then defective pouches can be removed efficiently, but device complexity increases
Solution Approach 1:
The sensor member, control system, and rejection mechanism are integrated into a unified automated quality control system. The sensor generates defect information that is processed by the control system, which automatically triggers the rejection mechanism, merging detection, decision-making, and execution functions into a coordinated system
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
The solution enables the identification and rejection of a variety of defects, ensuring higher product quality by automatically sorting out incomplete, mispositioned, or improperly sealed packets, improving the overall quality control process without manual inspection.
Implementation Method 1
The sensor member may work with reflected and/or transmitted radiation, e.g. light, UV, IR, microwaves, x-ray, ultrasound, beta-radiation or gamma-radiation
Data Source
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AI summary
The invention concerns a device (1 ) for producing portion packets (2) of a smokeless tobacco product or non-tobacco snuff product, comprising a forming arrangement (3) configured to form portion packets of the product from a supply of product material, a packaging arrangement (4) configured to fold and seal a packaging material (5) around the portion packets and comprising a unit for transversal sealing (11 ), a sensor member (12, 13) configured to generate information useful for identifying defect portion packets during operation of the device, a rejection system (7) configured to reject selected portion packets during operation of the device, and a control system (8) configured to receive the information generated by the sensor member and to control the rejection system. The sensor member is capable of generating data of at least a part of an individual portion packet during operation of the device, and the control system is configured to i) carry out a comparison between a) the data received from the sensor member and b) reference data and to ii) control the rejection system depending on a result of the comparison. The sensor member is arranged in association with the unit for transversal sealing, such as to be capable of generating data of portion packets that have been folded into the longitudinally folded strip of packaging material. The control system is provided with information on where on the strip of packaging material transversal seals (9) generated by the transversal sealing unit will be or have been placed. The invention also concerns a method for producing portion packets of a smokeless tobacco product or non-tobacco snuff product.