Rotational Tube Head Alignment via Signal Correlation
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Solution Overview
Problem
Existing methods for rotational alignment of tube heads relative to tube bodies in the food or cosmetics sector face challenges such as unreliable position detection, increased calibration and evaluation efforts, and high error rates due to variations in tube types and manufacturing tolerances, leading to slow cycle times and high reject rates.
Innovation Solution
A device and method that utilize sensor means to emit detection signals correlated with a reference signal to determine the absolute rotational position of the tube head, allowing for reliable and interference-insensitive alignment, using a variety of sensors like optical, inductive, or ultrasonic sensors, and correlating these signals to achieve precise positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If light barrier-based position detection is used to determine tube head rotational position, then position detection capability is provided, but reliability of position detection deteriorates due to sensitivity to manufacturing tolerances and variations in tube types
Solution Approach 1:
The system performs preliminary scanning of the entire tube head circumference to collect signal data before determining the final position. This preliminary action creates a data set that can be evaluated to identify the position indicator regardless of manufacturing variations, eliminating the need for manual calibration for each tube type.
Solution Approach 2:
The system creates a signal profile copy of the tube head's electromagnetic characteristics during scanning. By comparing the scanned signal pattern against expected patterns or by identifying unique signal features, the system can determine position without relying on precise geometric tolerances or manual calibration.
2Productivity
If traditional position detection methods are used, then alignment capability is provided, but productivity deteriorates due to slow cycle times and high reject rates
Solution Approach 1:
The system replaces mechanical position detection methods (such as physical markers or geometric features requiring precise tolerances) with electromagnetic field-based sensing. This substitution enables faster, non-contact measurement that is less sensitive to manufacturing variations, thereby improving both productivity and measurement precision.
Solution Approach 2:
The system performs preliminary scanning and signal analysis to pre-determine the position indicator location before the alignment operation. This preliminary action allows for rapid processing and reduces cycle time while maintaining precision through computational analysis of the signal data.
3Adaptability or versatility
If light barrier sensors are used for position detection, then detection capability is provided, but adaptability deteriorates when handling different tube types with different position indicator requirements
Solution Approach 1:
The electromagnetic sensing system provides universal detection capability that can identify position indicators on various tube head types without requiring tube-specific calibration. The system adapts to different tube geometries and indicator types by scanning and analyzing the electromagnetic signal patterns inherent to each configuration.
Solution Approach 2:
The system performs self-calibration by automatically scanning the tube head and identifying its unique signal characteristics during the measurement process. This self-service capability eliminates the need for manual calibration setup for each different tube type, thereby improving adaptability without increasing operational complexity.
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 simplifies and accelerates the alignment process, reduces reject rates, and allows for flexible handling of different tube head types without increased calibration efforts, ensuring quick and accurate merging of tube heads and bodies in automated production.
Implementation Method 1
sensor means for detecting a current rotational position of the tube head are designed such that they emit a detection signal corresponding to a rotating rotational movement of the tube head and this detection signal is subsequently correlated with a reference signal
Data Source
Figure 1~2
Figure 3a~4
Figure 5a~5b
AI summary
The invention relates to a device for the automatic rotational orientation of a tube head (16) relative to a preferably stationary tube body (14), wherein said device comprises sensor means (18) for sensing a current rotated position of the tube head or tube body having a position indicator (21), said device further comprising positioning means (12, 20) which interact with the sensor means and are designed to effect a rotary movement of the tube head or of the tube body in reaction to a control signal from a control unit (22). The sensor means are designed to generate a sensing signal corresponding to a rotary movement of the tube head or tube body and the control unit has means for correlating (24) the sensing signal with a reference signal and for generating a control signal from a characteristic value corresponding to a degree of correlation, in particular a maximum correlation or minimum correlation, for the positioning means.