Vision-Guided Container Capping for Thread Alignment and Torque Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing capping systems struggle to apply the correct and consistent torque to containers with randomly oriented threads, leading to difficulties in cap removal, potential leaks, and deterioration of contents, while also requiring high production speeds and efficient torque application.
Innovation Solution
A capping apparatus and method using artificial vision to identify the angular positions of container and cap threads, adjusting the capping head's speed and torque application based on these positions, ensuring precise and repeatable closure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the capping system applies high torque to ensure proper closing, then the closing reliability is improved, but the cap becomes difficult for users to remove
Solution Approach 1:
The system dynamically adjusts the torque parameter during the capping process based on real-time detection of thread engagement and container characteristics. By monitoring the rotational resistance and angular position, the control system modulates the applied torque to achieve optimal closing force that ensures reliability while remaining user-friendly for removal.
2Ease of operation
If the capping system applies low torque to ease cap removal, then the ease of operation is improved, but the closing reliability deteriorates with potential leaks
Solution Approach 1:
The system incorporates feedback mechanisms that continuously monitor the capping process through sensors detecting thread engagement, angular position, and torque application. This real-time feedback enables the control system to adjust torque dynamically, ensuring sufficient closing force is applied to prevent leaks while avoiding excessive torque that would make removal difficult.
3Productivity
If the capping head rotates at maximum speed to reduce empty rotation time, then the productivity is improved, but the torque control precision deteriorates
Solution Approach 1:
The capping head employs dynamic speed control, operating at maximum rotation speed during the initial phase to minimize empty rotation time and maximize productivity. As the thread engagement is detected and the torque peak approaches, the system automatically reduces speed to achieve precise torque control during the critical closing phase, thereby balancing productivity with precision.
4Manufacturing precision
If multiple capping heads are used to maintain torque precision at high speed, then the torque control precision is maintained, but the device complexity increases
Solution Approach 1:
The system replaces complex mechanical solutions with advanced control electronics and sensor systems. Instead of using multiple capping heads or complex mechanical timing mechanisms, the invention employs electronic control to detect thread engagement, calculate optimal torque, and precisely control the single capping head's operation, thereby maintaining torque precision while reducing device 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
Enables efficient torque control, reduces cap application time, and increases production speed with fewer capping heads, leading to improved repeatability and reduced apparatus size and maintenance costs.
Implementation Method 1
a first filming means for filming images having a first framing field oriented on the thread of the containers in sequential transit through said first framing field, a second filming means for filming images having a second framing field oriented on the thread of the caps
Data Source
AI summary
Containers housed with random angular orientation of their thread in a first plurality of seats present circumferentially in a first rotatable carousel, caps are housed with random angular orientation of their thread in a second plurality of scats present circumferentially in a second rotatable carousel, ae current image is acquired of the thread of the container in transit through a first framing field and a current image of the thread of the cap in transit through a second framing field, a current value is calculated of the angular position of the thread of the cap in transit through the second framing field and a current value of the angular position of the thread of the container in transit through the first framing field by comparing their current image with an optical reconstruction thereof preliminarily learned, and the screwing operation is programmed with the calculated value of the current angular position.