Adhesive Pattern Inspection Using Optical Copying and Digital Comparison
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current adhesive inspection methods for packaging materials are complex, expensive, and difficult to integrate with existing machinery, leading to inefficient verification of adhesive patterns, which can result in defective products and reputation damage.
Innovation Solution
A method and device that use a controller to compare detected adhesive patterns with pre-defined tolerance ranges, allowing for real-time inspection of adhesive beads on substrates using sensor arrangements and eliminating the need for a teach button, enabling standalone operation and integration with existing machines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If complex adhesive verification systems are used, then inspection accuracy is improved, but device complexity and integration difficulty increase
Solution Approach 1:
The patent uses optical copying to create an image of the adhesive pattern on the substrate. A camera captures the adhesive pattern, and this optical copy is then processed by a controller to verify whether the pattern matches the desired design. This replaces complex physical verification systems with a simpler optical copying and digital comparison approach.
Solution Approach 2:
The patent replaces complex mechanical verification systems with an optical and electronic system. Instead of using mechanical probes or complex sensor arrays to physically measure adhesive patterns, the invention uses a camera to optically capture the pattern and a controller to digitally compare it against the desired pattern, significantly simplifying the device while maintaining verification accuracy.
2Productivity
If adhesive patterns are applied with reduced material usage, then productivity is improved, but inspection difficulty increases
Solution Approach 1:
The optical copying capability allows the system to capture and analyze even small, reduced-amount adhesive patterns. By creating a digital image of the adhesive application, the system can verify patterns regardless of their size or material quantity, making it equally effective for both continuous and intermittent adhesive applications.
Solution Approach 2:
The controller provides immediate feedback by comparing the captured adhesive pattern image against the desired pattern. This real-time verification allows for instant detection of application errors, enabling quick correction and maintaining high productivity even when working with reduced material amounts that are more difficult to detect.
3Adaptability or versatility
If existing machines are integrated with inspection systems, then adaptability is improved, but device complexity increases
Solution Approach 1:
The inspection device is designed with universal applicability to existing adhesive application machines. The controller can receive various input formats (desired patterns from different sources) and the optical system can accommodate different adhesive types and application methods, allowing integration across multiple machine types without requiring custom complex integration solutions for each case.
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 provides a simple, cost-effective, and efficient means to verify adhesive patterns, ensuring correct application and reducing defects, thereby enhancing production efficiency and product quality.
Implementation Method 1
detecting a pattern of the discharged adhesive bead on the substrate when the substrate moves by means of a sensor arrangement
Data Source
AI summary
Inspection devices and methods for inspecting an adhesive pattern on a substrate are disclosed. The inspection device includes at least one sensor having a heat sensor head for detecting a pattern of the adhesive bead, and a controller. Reference data representing a desired adhesive pattern is initially provided to a controller. A predetermined tolerance range for the desired adhesive pattern is also provided to the controller. An adhesive bead is discharged onto a substrate from a nozzle. A pattern of the discharged adhesive bead is then detected by the sensor when the substrate moves. Signals representing the detected pattern are received from the sensor at the controller. Finally, the signals representing the detected adhesive pattern are compared to the tolerance range of the desired adhesive pattern.