Ultrasonic Packaging Flaw Detection for Film Break Prevention
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing packaging systems face frequent film breaks due to irregularities in loads, mechanical issues, and unpredictable changes in packaging material quality, leading to machine downtime and compromised containment force during shipping.
Innovation Solution
A method using ultrasonic sensors for time-limited response detection to identify flaws in packaging material, allowing for controlled stretch application and characterization of flaws, and adjusting packaging material tension to prevent film breaks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If thicker packaging material is used to increase strength and resistance to film breaks, then film break resistance is improved, but cost and environmental concerns worsen
Solution Approach 1:
The system performs preliminary detection of packaging material flaws using ultrasonic sensors before the material is used in wrapping operations. By identifying flaws such as gels, holes, carbon particles, and gauge bands in advance, the system can prevent film breaks before they occur during actual use, eliminating the need to use thicker material as a preventive measure.
Solution Approach 2:
The system continuously monitors packaging material quality by detecting reflected ultrasonic signals from the material web. When flaws are detected that would compromise film break resistance, the system provides feedback to adjust packaging material tension or alert operators, enabling real-time adaptation to maintain reliability without requiring thicker material.
2Reliability
If packaging material tension is lowered to reduce film breaks, then film break resistance is improved, but containment force deteriorates
Solution Approach 1:
By detecting packaging material flaws in advance using ultrasonic sensing before the wrapping operation begins, the system can prepare appropriate tension settings that account for potential weak points in the material. This preliminary detection allows the system to maintain optimal containment force while adjusting tension dynamically during operation to prevent film breaks at detected flaw locations.
Solution Approach 2:
The system dynamically adjusts packaging material tension based on real-time detection of flaws and reflection characteristics. Rather than using a static tension level, the system modulates tension during the wrapping process to accommodate detected irregularities, maintaining sufficient containment force overall while reducing local stress at flaw locations to prevent film breaks.
3Force
If additional layers of packaging material are added to maintain containment force, then containment force is improved, but productivity worsens due to increased wrapping time and material consumption
Solution Approach 1:
The ultrasonic detection system identifies packaging material flaws before they cause film breaks during wrapping operations. By knowing in advance where flaws exist and their severity, the system can optimize the wrapping process to use the minimum necessary material layers, avoiding unnecessary additional layers that would increase wrapping time and material consumption while still maintaining required containment force.
Solution Approach 2:
The system changes operational parameters such as tension, speed, and material feed rates based on real-time flaw detection. When flaws are detected, the system adjusts these parameters to compensate for the compromised material sections, allowing single-layer wrapping to maintain adequate containment force without requiring additional layers, thereby preserving productivity.
4Measurement precision
If ultrasonic sensors are used to detect packaging material flaws, then measurement precision is improved, but device complexity worsens
Solution Approach 1:
The system replaces complex mechanical inspection methods with ultrasonic sensing technology. Instead of using mechanical probes, visual inspection, or other physical examination methods that would require complex mechanical positioning and handling systems, the patent employs ultrasonic waves to non-contactedly detect packaging material flaws, simplifying the overall device architecture while achieving high measurement precision.
Solution Approach 2:
The ultrasonic waves serve as an intermediary between the sensor system and the packaging material. Rather than requiring direct mechanical contact or complex optical systems, the ultrasonic waves penetrate or reflect from the material web to carry information about flaws, acting as a simple yet effective mediator that enables precise detection with minimal system 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
The solution effectively detects and mitigates film breaks by adjusting tension, ensuring consistent containment force and reducing machine downtime, while evaluating packaging material quality to select appropriate materials for specific applications.
Implementation Method 1
an ultrasonic transducer towards a web of packaging material has not been received within a time-limited period associated with reflection of the ultrasonic signal by the web of packaging material
Implementation Method 2
at least a portion of the ultrasonic signal has likely passed through a flaw in the packaging material rather than being reflected thereby
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A method, apparatus and program product may evaluate a packaging material to determine various metrics associated with the packaging material. A test apparatus may be used to evaluate packaging material using a take up drum capable of sensing containment force imparted upon the drum by packaging material applied thereto, and in some instances, simulated flaws may be formed in a web of packaging material to evaluate a packaging materials response to such flaws when under tension.