Abstract:
Method for orienting tube components ( 2 ), such as heads or stoppers, comprising a step of measuring the angular position ( 6 ) of a component followed by a step of orienting said component, in which step the angular correction of the component is determined especially while taking into account the measured signal ( 8 ); method characterized in that said angular correction is also determined while taking into account a modelled parasitic signal ( 15 ). The invention also comprises a device using said method.

Description:
CORRESPONDING APPLICATIONS 
       [0001]    The present application claims priority over the prior European application no. EP14187985.8 filed on 7 Oct. 2014 in the name of Aisapack Holding SA, the content of this prior application being incorporated for reference in its entirety in the present application. 
       FIELD OF THE INVENTION 
       [0002]    The invention applies to the field of flexible tubes, and more particularly the packaging tubes for liquid or viscous products in which the tube head or the stopper is oriented facing the tube body. 
       STATE OF THE ART 
       [0003]    For tubes for cosmetic, food or oral care use, it is often necessary to orient a component of the tube head relative to the flexible part forming the body of the packaging. The term tube head denotes, for example, a snap-on stopper fixed by snap-fitting onto the neck of the shoulder. For these stoppers, it is often desirable for the opening thereof to be oriented relative to the printing of the tube body. Other snap-on stoppers are screwed onto the neck of the tube. In this case, the orientation of the shoulder relative to the tube body is necessary for the stopper to be ultimately located in the desired position. More generally, when the tube head does not exhibit rotation symmetry, an orientation operation is necessary to orient the tube head relative to the tube body. 
         [0004]    The orienting of the tube heads relative to the tube body has been known for a long time by those skilled in the art and is performed automatically on the production machines. The principle currently used described in  FIG. 1  consists in rotating a component  2  locally including a notch  3 . The beam  5  emitted by the laser cell  11  is obstructed by the component  2  in rotation ( FIG. 1A ) except when the notch  3  passes in front of the beam ( FIG. 1B ). At the moment of this alignment, the laser beam  5  emitted by the cell  11  is reflected by the mirror  12  and detected in return by the cell  11  ( FIG. 1B ). The signal emitted by this type of cell is illustrated ( FIG. 1C ). The obtained signal  8  is plotted as a function of the angular position  6  of the component  2 . The signal takes the form of a pulse  9  corresponding to the alignment of the laser beam  5  and of the notch  3  during the rotation. The use of a servomotor to rotate the component  2 , coupled with the device for detecting the notch  3  described previously makes it possible to then orient the component relative to a reference position  7 . 
         [0005]    Although very widely used, the system described previously comprises a number of drawbacks. A first drawback is linked to the geometry of the notch which is sometimes difficult to detect because of its form or its size. In some cases, the positioning of the cell  11  requires very precise settings, resulting in lengthy and costly setting times. Another drawback with this detection system is linked to the deformations of the components  2  by the clamps which hold the component  2  during the rotation. Finally, many components cannot be oriented by this device because their geometry is unsuitable (no notch  3 ) or because of their lack of opacity to the laser beam. 
         [0006]    The patent application WO2011116902 proposes the orientation method illustrated in  FIG. 2  in order to mitigate the abovementioned difficulties. In this application, it is proposed to arrange the cell  11  as illustrated in  FIG. 2A  and to analyze the return signal received by the cell during the rotation of the component  2 . A reference signal  16  is defined for the position of the component  2  oriented in the reference angular position  7  ( FIG. 2B ). The orientation method proposed by Schulthess consists in acquiring the signal corresponding to the stopper to be oriented ( FIG. 2C ) and in comparing this signal  8  with the reference signal  16  in order to determine the phase difference  10 . More specifically, Schulthess proposes computing the correlation between the signal  8  and the signal  16  as a function of the phase difference. The alignment is found for the phase difference  10  corresponding to the best correlation. 
         [0007]    The orientation method proposed in the patent WO2011116902 makes it possible to solve a certain number of problems encountered subsequently. However, this method presents a number of drawbacks. The main drawback is illustrated in  FIG. 3 .  FIG. 3A  shows an example of deformation of the component  2  when it is held by the clamps  16  of the rotating tool. The views a, b and c of  FIG. 3A  represent the component  2  deformed by the clamps  16  for three angular positions of the component  2  relative to the clamps  16 .  FIG. 3B  represents the signals  8   a,    8   b  and  8   c  respectively in the views a, b, and c of  FIG. 3A . The signals  8   a,    8   b  and  8   c  are obtained during the rotation of the component  2  in front of the cell  11 . In these signals, the characteristic peaks  9   a,    9   b  and  9   c  correspond for example to the notch  3 .  FIG. 3B  illustrates the best correlation obtained between two signals  8   a,    8   b  and  8   c  according to the method proposed by Schulthess. It can be seen in  FIG. 3B  that the characteristic peaks  9   a ,  9   b  and  9   c  of the signals respectively denoted  8   a,    8   b  and  8   c  are not superimposed. This result shows that, in this precise case, the method proposed in the patent WO2011116902 cannot be used. In this precise case, the alignment of the characteristic peaks  9   a,    9   b  and  9   c  would not lead to a minimum or maximum correlation between the signals  8   a,    8   b  and  8   c.  Generally, the method proposed by Schulthess cannot be applied when the characteristic signal of the component  9  is mixed with an interfering signal  13  with a phase that is totally independent. The method proposed by Schulthess does not in particular make it possible to orient the components deformed by the holding clamps during the rotation. Nor does this method apply when the tool generates a significant interfering signal, which is generally the case with industrial devices operating automatically. The interfering signal comprises parts linked to the rotating tool (functional plays, alignment defects, deformation of the component), others linked to positioning irregularities of the component in the rotating tool, and others linked to the environment (machine vibrations). 
         [0008]    The method proposed in the invention described below makes it possible to mitigate the abovementioned drawbacks. 
       DEFINITIONS 
       [0009]    In the present text, the term “component” corresponds to the number  2  in the figures and refers to the element of the tube head to be oriented relative to the tube body. The component is, for example, a stopper. 
         [0010]    The term “notch” corresponds to the number  3  and is used to designate an element or several elements of the component making it possible to define an orientation by forming a detectable reference on the component  2 . 
         [0011]    These elements can be linked to the geometry of the component, to its surface condition, to its composition, to its color. 
         [0012]    The term “cell” corresponding to the number  11  and generally designates a laser cell making it possible to emit and receive a signal. More generally, the term cell designates a device which emits a signal and receives at least a part of this signal having interacted with the component during its rotation. 
         [0013]    The term “beam” corresponding to the number  5  refers to the signal emitted by the cell. 
         [0014]    The term “interfering signal” corresponding to the number  13  designates the part of the signal received by the cell not comprising any information linked to the orientation of the component. 
         [0015]    The term “model of the component signal” corresponding to the number  14  designates the part of the model comprising information specific to the component and useful for its orientation. 
         [0016]    The term “model of the interfering signal” corresponding to the number  15  designates the part of the model comprising information of no use to the orientation of the component. The interfering model comprises, for example, the information linked to the deformation of the components in the rotating tool, to the positioning irregularities of the components in the rotating tool, to the functional plays of the tool, to the vibrations, etc. 
       SUMMARY OF THE INVENTION 
       [0017]    The invention relates to a method for orienting components as defined in the claims and a device for implementing said method. 
         [0018]    The invention proposes, in particular, an orientation method based on the rotating of the component to be oriented, the emission and the reception of a signal which interferes with the component. The information contained in the return signal, called “measured signal”, is used to define the position of the component in the rotating tool. Then, the deduced angular correction is applied to orient the component in the desired position. 
         [0019]    According to one embodiment, the invention comprises a first phase consisting in creating a model of the signal measured in a first phase called “modelling phase”. Advantageously, the model of the measured signal is made up of the combination of a first signal representative of the component called “model of the component signal” and at least one second signal characteristic of the measurement apparatus and of its environment called “model of the interfering signal”. 
         [0020]    According to the invention, the combination of the model of the component signal and of the model of the interfering signal can for example be multiplicative or additive or of more complex form. A preferential embodiment of the invention consists of an additive combination. 
         [0021]    According to the invention, the modelling phase is necessary for each new component and requires the acquisition of the measured signal for at least five components oriented randomly, and preferably at least ten components. The information contained in these measured signals is used to define the model of the signal. 
         [0022]    On completion of the modelling phase, the measured signal is systematically replaced by the model of the signal and consequently broken down into a component signal model and a model of the interfering signal. The phase of the model of the component signal indicates the angular position of the component. 
         [0023]    The method comprises a second phase called “calibration phase” consisting in defining the reference position of the component corresponding to the desired angular orientation. This phase requires the intervention of the operator who defines the phase difference required for a randomly oriented component. The phase difference is compared to the phase of the model of the component signal and the reference position is defined. 
         [0024]    The method comprises a third so-called automatic orientation or production phase. During the production phase, the components are oriented automatically. The orientation method comprises a first step of replacement of the measured signal by the model of the signal. This operation consists at least in varying the phase of the model of the component signal and identifying the phase called “component phase” giving the best balance between the measured signal and the model of the signal. The best balance is obtained by minimizing the sum of the deviations squared between the measured signal and the model of the signal. The method then comprises a second step which consists in modifying the angular position of the component by the value of the phase difference between the component phase and the reference position defined previously. 
         [0025]    According to the invention, the search for the component phase can be performed by jointly varying the phase of the component model and the phase of the interfering model and finding the best balance between the model of the signal and the measured signal. The preferred method consists in varying only the phase of the component model. 
         [0026]    A first advantage of the invention is its robustness, which allows it to be used in industrial environments where the interfering noises have significant amplitudes. It notably allows the orientation of components even if the amplitude of the interfering signals is very much higher than the amplitude of the signal specific to the component. 
         [0027]    A second advantage of the invention is the possibility of orienting components at a high production rate. The invention for example makes it possible to orient components deformed by the rotating tool. The deformation of the component can be a function of its position in the rotating tool. The component deformation signal consequently cannot be used to orient the component and becomes an interfering signal. The invention makes it possible to separate the information linked to the orientation of the stopper and the interfering information linked to its deformation. The invention similarly makes it possible to separate the interfering information linked to the variations of positioning of the component in the rotating tool, or the interfering information linked to the defects of the rotating tool (out of round, vibrations, alignment defect). 
         [0028]    This method makes it possible to define the angular position of the component even if the level of the interfering noise is inherent in the measurement system and its environment is of an amplitude higher than the signal characteristic of the component to be oriented. 
         [0029]    The present invention is defined by the features contained in the independent claims, the dependent claims defining more particular embodiments thereof. 
     
    
     
       BRIEF DESCRIPTION OF THE FIGURES 
         [0030]      FIG. 1  comprising  FIGS. 1A, 1B and 1C  represents the orientation device and method of the prior art and commonly used in the industry to orient components relative to tube bodies. 
           [0031]      FIG. 1A  illustrates a random position of the component in the orientation device. 
           [0032]      FIG. 1B  represents the detection of the notch  3  of the component during the orientation process. 
           [0033]      FIG. 1C  represents the signal resulting from the rotation of the component. 
           [0034]      FIG. 2  comprising  FIGS. 2A, 2B and 2C  illustrates a second orientation method described in the patent application WO2011116902. 
           [0035]      FIG. 2A  represents the orientation device used. 
           [0036]      FIG. 2B  illustrates the reference signal corresponding to a known angular position of the component. 
           [0037]      FIG. 2C  represents a signal measured for a random position of the component. 
           [0038]      FIG. 3  comprising  FIGS. 3A and 3B  illustrates a drawback of the method proposed in the patent application WO2011116902. 
           [0039]      FIG. 3A  shows the deformation of the component  2  in the clamps  16  of the rotating tool. The views a, b and c illustrate different angular positions of the component  2  in the clamps  16 . 
           [0040]      FIG. 3B  illustrates the best correlation obtained between the signals  8   a,    8   b  and  8   c  corresponding respectively to the views a, b and c of  FIG. 3A . The best correlation between the two signals does not correspond to an identical orientation of the components. 
           [0041]      FIG. 4  illustrates the orientation device used in the invention. 
           [0042]      FIG. 5  comprising  FIGS. 5 a , 5 b  and 5 c    illustrates the phase of creation of a signal model. 
           [0043]      FIG. 5A  illustrates the acquisition of the signals  8   a,    8   b,    8   c,    8   d,    8   e  and  8   f  corresponding to a random orientation of the components a, b, c, d, e and f during the modelling phase. 
           [0044]      FIG. 5B  illustrates the model of the component signal obtained from the modelling phase. 
           [0045]      FIG. 5C  illustrates the model of the interfering signal obtained from the modelling phase. 
           [0046]      FIG. 6  illustrates the phase difference between the model of the component signal and the reference position. 
           [0047]      FIG. 7  shows the orientation method according to the invention. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0048]    The general principle of the invention illustrated in  FIG. 4  is an orientation device and method based on the rotating of the component  2  to be oriented, the emission and the reception of a signal  5  which interferes with the component. The information contained in the return signal called “measured signal” is used to define the position of the component in the rotating tool. Then, the deduced angular correction is applied to orient the component in the desired position. 
         [0049]    The orientation device illustrated in  FIG. 4  comprises at least one cell  11  which emits and receives a signal  5  interfering with the component  2  in rotation about an axis  4 , means for rotating the component  2 , and means for processing the information from the cell  11 . The cell  11  can be made up of two independent entities; a first for emitting the signal  5 , a second for receiving the signal having interfered with the component. 
         [0050]    More specifically, the device for orienting components according to the present invention comprises at least one cell  11  intended to emit and receive a signal  5  (preferably an optical signal) and information processing means  12 , for example a system of computer type or other equivalent system. 
         [0051]    According to a preferential embodiment of the invention, the cell  11  is an optical sensor of energy type which is linked to the information processing means  12 . According to this preferential embodiment, said means  12  mainly comprise an independent processor  12 ′. This processor  12 ′ notably performs the processing of the information sent by the cell  11  and by a coder  4 ′ situated on the axis of the component rotating tool. Said coder  4 ′ informs said processor  12  of the angular position of the rotating tool. When the phase difference of the component relative to the reference is computed, the processor  12 ′ interacts with the control of the component rotating motor in order to orient said component in the correct position. 
         [0052]    According to the preferential embodiment, the processor  12 ′ is also linked to a display screen  20  which allows the operator to perform the initial settings and track the orientation of the components  2  during production. 
         [0053]    The device described above is particularly advantageous because it makes it possible to orient components  2  at a high production rate. The use of an orientation processor  12 ′ independent of the processor of the machine makes it possible to process the information relating to the orientation of the components  2  in parallel with the information linked to the driving of the machine and processed by the processor of the machine. 
         [0054]    Another advantage of the proposed device is linked to its modularity. The device described in the present invention can be implemented with no great difficulty on machines that differ greatly in their operation or in their control mode. The device is also modular because it can be upgraded either at the information processing level or at the hardware level. This upgrading can be done independently of the rest of the machine. 
         [0055]    The core of the invention lies notably in an orientation method whose main steps are described in  FIG. 7 . This method comprises at least three phases; a first so-called signal modelling phase, a second so-called calibration phase, a third so-called automatic orientation phase. 
         [0056]    The modelling phase consists in acquiring a number of signals relating to components oriented randomly; then in executing an appropriate digital processing making it possible to define a model of the signal. The model of the signal according to the invention is made up of at least a model of the component signal and a model of the interfering signal. According to the invention, the model of the component signal comprises the information specific to the component and useful for defining its orientation whereas the model of the interfering signal comprises the information characteristic of the measurement apparatus and its environment and consequently of no use to the orientation of the component. In the model, the phase or the angular position of the model of the component signal is variable since it is precisely this angular position which has to be found in order to ultimately orient said component. 
         [0057]    The modelling phase is done automatically by the machine, without intervention from the operator. For the defined model to be sufficiently robust, it is necessary for the model of the interfering signal to take account of the disturbances that can occur during production. For this reason, the acquisition of the signals for the modelling phase is performed in the production environment, that is to say with a machine setting identical to that used for the production. A minimum number of components must be used to give an account of all the disturbances that can occur during production and in order to obtain a distribution of the orientation of the components in the device that is sufficiently random. From experience, it has been found that the robustness of the model requires the successive acquisition of at least five signals corresponding to five components oriented randomly in the rotating device. Preferentially, at least ten signals are used to define the model. A greater number of signals may be necessary when the components are of poor quality and exhibit significant dimensional variations, or when the machine is worn or poorly adjusted. Generally, the packaging machines requiring this orientation operation operate at rates higher than 60 parts per minute and per station. The acquisition time for ten signals is therefore less than 6 seconds which indicates that a greater number of signals could be used without that having any significant impact on the machine setting time. 
         [0058]    The modelling phase requires the search for the signal model from the signals acquired. An appropriate digital processing is performed on the basis of these data to define the model of the component signal and the model of the interfering signal. The model of the signal results from the combination of the model of the component signal and of the model of the interfering signal. Preferentially, the model of the signal results from an additive combination of the component signal and of the interfering signal. Multiplicative combinations or combinations of more complex form can also be envisaged. According to the invention, at least the phase of the component model is variable. The phase of the component signal model indicates the angular position of the component in the rotating tool. According to a preferential embodiment of the invention, the phase of the interfering signal model is constant, which indicates that the interferences are primarily linked to the tool rotating said component. 
         [0059]    The component orientation method then comprises a calibration phase as indicated in  FIG. 7 . The aim of the calibration phase is to define the desired oriented position. This phase entails the intervention of the operator who indicates the value of the angular rotation to be applied (that is to say the value of the phase difference) to orient a component positioned randomly in the orientation device. The calibration phase comprises a number of steps. A first step consists in acquiring the signal for a stopper positioned randomly in the rotating tool. In a second step, the phase of the model of the component signal is then determined in order to minimize the deviation between the measured signal and the model of the signal. The phase of the component model that makes it possible to minimize the deviation defines the angular position of the component in the rotating tool. In the third step, the operator indicates the phase difference value to be applied to obtain the desired orientation. This last step makes it possible to define the reference angular position of the component signal model which corresponds to the oriented position of said component. 
         [0060]    As indicated in  FIG. 7 , the third phase of the orientation method is the automatic orientation phase or production phase. During this phase the machine automatically orients the components at a high production rate. The automatic orientation phase comprises at least the succession of a step of acquisition of the signal, a step of searching for the phase of the component model, a step of computation of the phase difference to be applied relative to the reference position (oriented position), and, finally, a step of orientation of the component by applying the phase difference. 
         [0061]    The automatic orientation phase must be performed within very short times given the rate of production. A major advantage of the invention is the possibility of achieving very high production rates. In the second step, the use of the model of the signal to define the phase of the signal allows for very short computation times. In this second step, there is a great benefit, by virtue of the model, in being able to replace the measured signal by a signal model resulting from the combination of a model of the component signal and a model of the interfering signal. This substitution is obtained by varying the phase of the model of the component signal and by comparing the model of the signal with the measured signal. The phase of the model of the component signal is determined when the deviation between the signal model and the measured signal is minimal. The method preferentially used to minimize the deviation between the signal model and the measured signal consists in minimizing the sum of the deviations squared between the two signals. The use of a model to perform these operations is a major benefit because the model of the signal can be broken down into a model of the component signal and a model of the interfering signal. 
         [0062]    According to the invention, the orientation method also makes it possible to quantify the reliability of the orientation based on the analysis of the deviation between the model of the signal and the measured signal. The reliability value obtained can be used to eject the components whose orientation is deemed uncertain. 
         [0063]    The method described in  FIG. 7  offers great robustness because the interfering noises are subtracted. The advantage of the method lies in the use of a model for the interfering noises and a model characteristic of the component and of its orientation. 
         [0064]      FIG. 5  comprising  FIGS. 5A, 5B and 5C  illustrates the modelling phase.  FIG. 5A  shows an example of acquisition of measured signals  8   a  to  8   f  as a function of the angular position  6  of the rotating tool. As illustrated in  FIG. 5A , it is possible to identify, in these signals, the peaks  9   a  to  9   f  whose phase varies and which are characteristic of the respective orientation of the components a to f in the rotating tool. It can also be seen that said measured signals  8   a  to  8   f  exhibit an interfering noise  13   a  to  13   f  in phase with the rotating tool. An appropriate processing of all the signals  8   a  to  8   f  makes it possible to obtain the model of the signal illustrated in  FIGS. 5B and 5C .  FIG. 5B  represents the model of the component signal  14  whose phase is variable and which is representative only of the component and of its orientation. In this signal, the peak  9  which is the model of the peaks  9   a  to  9   c  of  FIG. 5A  is easily identifiable.  FIG. 5B  also shows a series of secondary peaks which can be used also for the orientation of the component but which are impossible to identify visually in the measured signals of  FIG. 5A . This example shows that the method according to the invention makes it possible to identify characteristics of the component which are undetectable in the measured signal because of the interfering noises.  FIG. 5C  illustrates the model of the interfering signal  15  representative of the interfering noises  13   a  to  13   f  of  FIG. 5A . In the model of the interfering signal illustrated in  FIG. 5C , only the noises not randomly occurring are retained. In the example of  FIG. 5 , the model of the interfering signal  15  is in phase with the rotating tool. In the example of  FIG. 5 , the model of the signal corresponds to the sum of the model of the component signal illustrated in  FIG. 5B  and of the model of the interfering signal illustrated in  FIG. 5C . 
         [0065]      FIG. 6  illustrates the operation performed during the calibration phase. This operation consists in determining the reference position  7  corresponding to the desired orientation of the component. During this calibration phase, the operator defines the angular rotation, that is to say the phase difference  10  to be applied to the component to obtain the desired orientation. As illustrated in  FIG. 6 , the phase difference is computed from the component model and not from the measured signal. 
         [0066]    The orientation method described in the invention is particularly relevant for orienting stoppers relative to printed tube bodies. In particular, the invention makes it possible to orient clipped-on stoppers of “snap-on” type in order for the opening of the tube to be in accordance with the printing. The invention notably makes it possible to orient thin stoppers which are deformed in the clamps of the rotating tool. 
         [0067]    The invention makes it possible to improve the accuracy of the orientation of the component because the phase difference  10  to be applied is defined with great accuracy. 
         [0068]    The invention makes it possible to orient the components in a very short time, which makes it possible to achieve high production rates. 
         [0069]    The invention makes it possible to reduce the rejects linked to dimensional variations of the components (deformations, removals) or color variations. 
         [0070]    The invention makes it possible to considerably reduce the setting times upon a change of component (geometry, diameter, color). 
         [0071]    The embodiments of the present invention are given as illustrative examples and should not be considered to be limiting. Variants are possible within the scope of the protection claimed, notably by using equivalent means. 
         [0072]    For example, the signal emission and reception cell ( 11 ) could be in motion about the component which, for its part, would remain fixed. 
         [0073]    Preferably, the cell is positioned on an axis at right angles to the axis of rotation of the object/component to be oriented. A position of the cell according to a plane parallel to the axis of orientation of the object can also be used if the information contained in the reading plane comprises information relating to the angular orientation of the component (for example the top surface of the object). 
         [0074]    More generally, the positioning of the axis of the cell can be set according to different orientations relative to the orientation axis. 
         [0075]    Any reference that can be detected on the component can be used in the context of the present invention to determine the position of said component and orient said component according to the principles of the present invention. 
         [0076]    If the present description mentions an application for tube components, this is not limiting and other applications can be envisaged in which there is a desire to rapidly orient parts arranged randomly. 
         [0077]    The signal used for the measurement and orientation can be an optical signal or other signal (electrical, magnetic, etc.) which is transformed if necessary for it to be processed according to the principles of the present invention.