Apparatus and method for web twist defect correction
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Solution Overview
Problem
Current web processing operations face inefficiencies due to waste generation, machine downtime, and quality control issues, particularly in the production of disposable products like diapers, where defective products are identified late in the process, leading to unnecessary material recycling and reduced production yield.
Innovation Solution
Implementing a web processing system with integrated visual inspection and correction mechanisms that detect and correct orientation issues in real-time, such as twists in narrow webs, and flagging defective products to prevent further processing, thereby minimizing waste and ensuring proper assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If web processing operations continue without real-time inspection, then production speed is maintained, but waste increases due to late defect identification
Solution Approach 1:
The patent implements real-time visual inspection that detects defects during web processing operations, allowing identification of orientation errors and defects before they result in waste. The system captures images of the moving web, processes them to detect defects, and flags problematic areas for correction before they cause material waste or production delays.
2Measurement precision
If real-time visual inspection is implemented, then defect detection accuracy improves, but device complexity increases
Solution Approach 1:
The patent replaces complex mechanical inspection systems with a visual inspection system using cameras and image processing. Instead of using mechanical sensors or physical contact methods to detect defects, the system uses optical imaging and computational algorithms to identify orientation errors, twists, and other defects in the web material during processing.
3Manufacturing precision
If defective products are flagged and corrected in real-time, then product quality improves, but processing time increases
Solution Approach 1:
The patent implements a feedback system where the visual inspection results are immediately used to control downstream processing equipment. When a defect is detected, the system provides real-time feedback to flag the defective area and can automatically adjust processing parameters or divert the defective portion, ensuring high product quality without significant processing time delays.
Data Source
AI summary
Apparatus and methods are provided to minimize waste and improve quality and production in web processing operations. The apparatus and methods provide defect detection in deposition of acquisition material, which on current machines frequently flips and is difficult to detect when it has flipped causing manufacturers to scrap thousands of products. Using the present invention, defects are able to be detected by discerning a difference in the appearance from side to side with a vision camera, and an acquisition inverter can flip the material to a correct orientation.