Adhesive Position Detection on Color-Matched Packaging Blanks
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Solution Overview
Problem
Existing devices fail to inspect position shifts of adhesives on packaging container blanks that have colors identical or similar to the blank, leading to manufacturing defects.
Innovation Solution
An inspection device with an illumination unit and imaging unit configured to illuminate and image the blank from different directions, utilizing brightness differences to detect and judge the position of adhesives on the blank, and an image processing unit to set a target arrangement area and judge adhesive placement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional optical inspection is used to detect adhesives on blanks, then inspection speed is maintained, but detection precision deteriorates when adhesive color matches blank color
Solution Approach 1:
The patent applies local quality by creating specific illumination conditions that generate brightness differences only at the adhesive location. The illumination unit is positioned to create specular reflection from the adhesive surface, making the adhesive appear bright against the darker blank background, thereby enabling detection without requiring complex multi-spectral imaging systems.
Solution Approach 2:
The patent transitions from detecting adhesive based on color (2D image space) to detecting based on brightness/intensity (adding a luminance dimension). By positioning the illumination unit at a specific angle to create specular reflection, the system converts the adhesive's surface property into a brightness contrast that can be detected by conventional imaging sensors, effectively adding a detection dimension.
2Illumination intensity
If illumination direction is perpendicular to blank surface, then uniform illumination is achieved, but adhesive brightness contrast with blank is lost
Solution Approach 1:
The patent deliberately introduces asymmetry in the illumination geometry. Instead of perpendicular illumination, the illumination unit is positioned at a specific angle (e.g., 45 degrees) relative to the blank surface. This asymmetric arrangement creates specular reflection from the adhesive that appears bright to the imaging unit, while the blank surface appears darker, thereby achieving adhesive detectability through directional illumination.
3Shape
If adhesive color is made identical to blank color for aesthetic purposes, then appearance quality is improved, but inspection capability deteriorates
Solution Approach 1:
The patent effectively changes the optical appearance of the adhesive under inspection conditions through controlled illumination. By using directional lighting at a specific angle, the adhesive surface produces specular reflection that appears bright white, while the blank surface appears darker. This illumination-induced appearance change enables detection of adhesives that are color-matched to the blank for aesthetic purposes.
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 accurate detection and correction of adhesive position shifts, ensuring proper assembly of packaging containers and reducing manufacturing defects.
Implementation Method 1
an illumination unit for illuminating, from a first direction, the blank which includes the test object; an imaging unit for taking an image of the blank including the test object from a second direction that is different from the first direction
Implementation Method 2
an image processing unit for identifying, based on brightness, a relative position of the test object with respect to the blank in the image data
Data Source
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AI summary
In order to manufacture a packaging container for a smoking article, positional offset of an adhesive applied to a blank is determined, the adhesive having the same color or a similar color to the blank. In order to determine the positional offset of a test object having a similar color to a blank which can be assembled as a packaging container for a smoking article, the test object being disposed on the blank, the inspection device of the present invention is provided with an illumination unit for illuminating the blank including the test object from a first direction, an imaging unit for capturing an image of the blank including the test object from a second direction different from the first direction and generating image data, and an image processing unit for specifying the position of the test object relative to the blank on the basis of brightness in the image data.