Acoustic Wave Detection for Moving Cardboard Defects

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Solution Overview

Problem

Current methods for evaluating the quality of cardboard laminates, such as crush tests, are destructive and cannot be applied to all tubes during a production run, failing to detect defects in a non-destructive manner.

Innovation Solution

A non-destructive, in-line system that emits acoustic waves towards moving cardboard structures, converting them into mechanical waves and capturing the propagated waves to analyze defects based on predetermined propagation properties, allowing for contactless and continuous quality control.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If destructive crush tests are used to evaluate radial compression strength, then measurement precision is improved, but productivity deteriorates because tubes must be destroyed and cannot be tested continuously

Engineering Contradiction:

Improveradial compression strength measurementVSAvoidproduction speed

Core Design Contradiction:

Measurement precisionVSProductivity

Solution Approach 1:

The patent replaces the mechanical crush test system with an acoustic wave-based detection system. Acoustic waves are emitted toward the cardboard tube, converted to mechanical waves that propagate through the tube, and then converted back to acoustic waves for detection. This substitution allows non-destructive testing that does not interfere with production flow, thereby maintaining both measurement precision and productivity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces acoustic waves as an intermediary medium to detect tube quality. Instead of directly applying mechanical force that destroys the tube, acoustic waves serve as a mediator that carries information about the tube's structural integrity without causing damage, enabling continuous testing at production speed.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Productivity

If random sampling tests are used to maintain productivity, then production speed is maintained, but measurement precision deteriorates due to incomplete defect detection

Engineering Contradiction:

Improveproduction speedVSAvoiddefect detection accuracy

Core Design Contradiction:

ProductivityVSMeasurement precision

Solution Approach 1:

The patent implements continuous quality control by integrating the acoustic detection system into the production line. The system continuously emits acoustic waves and detects the resulting mechanical waves as tubes pass through, enabling 100% inspection rather than random sampling. This continuous action maintains production speed while significantly improving defect detection accuracy.

Inventive Principle:

Principle #20Continuity of useful action

3Productivity

If non-destructive methods are used to maintain productivity, then production speed is maintained, but measurement precision deteriorates compared to destructive tests

Engineering Contradiction:

Improveproduction speedVSAvoidquality evaluation accuracy

Core Design Contradiction:

ProductivityVSMeasurement precision

Solution Approach 1:

The patent utilizes mechanical vibration in the form of acoustic waves to detect tube quality. By emitting acoustic waves that convert to mechanical waves propagating through the tube structure, the system detects vibrations and wave propagation characteristics that reveal internal defects. This vibration-based approach provides accurate quality evaluation non-destructively, maintaining both productivity and measurement precision.

Inventive Principle:

Principle #18Mechanical vibration

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 the detection and identification of defects in cardboard structures without damaging the products, providing real-time feedback for correcting manufacturing issues and ensuring compliance with quality standards.

Implementation Method 1

The acoustic waves are converted into mechanical waves, propagating through the moving cardboard structure

Methodology Applied

Scientific EffectAcoustic wave to mechanical wave conversion: Acoustic Radiation Pressure

Implementation Method 2

The captured acoustic waves result from a conversion of the propagated mechanical waves through the moving cardboard structure

Methodology Applied

Scientific EffectMechanical wave to acoustic wave conversion: Acoustic Emission

Data Source

PatentUS11209403B2In-line, contactless and non-destructive method and system for detecting defects in a moving cardboard structure

Publication Date: 2021.12.28 ABZAC CANADA INC

AI summary

An in-line, contactless and non-destructive method for detecting and identifying defects in a moving cardboard structure is provided, as well as the associated system. The cardboard structure is of the type made of layered paper plies, such as cardboard tubes for example. The method includes the steps of emitting acoustic waves with predetermined frequencies toward the moving cardboard structure. The acoustic waves are converted into mechanical waves propagating through the moving cardboard structure. The method also includes a step of capturing the acoustic waves propagated, wherein said captured acoustic waves result from a conversion of the propagated mechanical waves through the moving cardboard structure. The method also provides steps of analyzing the captured acoustic waves; and detecting and identifying defects in the moving laminated cardboard structure based on predetermined propagation properties measured from the captured acoustic waves.