Adhesive Pattern Inspection Using Thermal Sensor Detection
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Solution Overview
Problem
Current adhesive inspection methods for packaging materials are complex, expensive, and not easily integrated into existing systems, leading to potential defects and costly returns due to inadequate adhesive application verification.
Innovation Solution
A method and device for inspecting adhesive patterns on substrates using a controller that compares detected patterns with pre-defined tolerance ranges, allowing for standalone operation without the need for a teach button, and utilizing infrared sensors for contactless detection of adhesive beads to ensure accurate application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If complex and expensive adhesive verification systems are used, then measurement precision and reliability are improved, but device complexity and cost increase significantly
Solution Approach 1:
The patent replaces complex mechanical or optical verification systems with a simple thermal sensor-based detection system. The thermal sensor detects heat radiation from the adhesive pattern, providing sufficient measurement precision without requiring complex mechanical components or sophisticated optical systems. This substitution dramatically reduces device complexity while maintaining adequate detection accuracy for adhesive verification.
2Measurement precision
If traditional adhesive verification systems are implemented, then measurement precision is improved, but ease of operation and integration deteriorate due to programming requirements and setup complexity
Solution Approach 1:
The thermal sensor system operates autonomously without requiring programming or complex setup procedures. The sensor naturally detects heat radiation from the adhesive, and the system self-adjusts to provide verification. This eliminates the need for operators to program detection parameters or perform complex calibration procedures, making the system extremely easy to operate while maintaining measurement precision.
3Adaptability or versatility
If machine speed changes are accommodated by traditional systems, then adaptability is improved, but reliability deteriorates due to false detection and inspection errors
Solution Approach 1:
The thermal sensor system dynamically adapts to changing machine speeds without compromising detection reliability. The thermal detection method inherently responds to the actual physical state of the adhesive regardless of production speed. The system naturally adjusts its detection timing and parameters based on real-time thermal signatures, maintaining high reliability across varying operational speeds without producing false detections.
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 easy-to-use adhesive inspection method that reduces defects and returns by ensuring accurate adhesive application, improving production efficiency and reducing material waste.
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
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AI summary
The invention relates to a method for inspecting an adhesive pattern on a substrate (34), comprising the steps of providing reference data representing a desired adhesive pattern into a controller (102); providing a stored and pre-determined tolerance range for the desired adhesive pattern in the controller (102); discharging an adhesive bead (38, 39, 40) onto a substrate (34) from a nozzle (8); detecting a pattern (37) of the discharged adhesive bead (38, 39, 40) on the substrate (34) when the substrate moves, by means of a sensor arrangement (43); receiving signals representing the detected pattern (37) from the sensor arrangement (43) at the controller (102); and comparing said signals representing the detected adhesive pattern (37) with the tolerance range of the desired adhesive pattern.