Box-Making Tape Affixing Detection via Unreeling Timing
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Solution Overview
Problem
Existing cardboard box-making apparatuses rely on visual inspection to confirm tape affixing, which is inefficient and prone to errors when using colored or patterned tape, lacking an effective method for automatic detection.
Innovation Solution
A box-making apparatus equipped with a tape-affixing section, detection unit, and control unit that assesses tape affixing through the unreeling action and timing, using sensors to detect abnormalities without visual inspection, ensuring reliable detection of tape affixing on cardboard boxes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If visual inspection by worker is used to confirm tape affixing, then detection accuracy is maintained, but productivity decreases and manual labor increases
Solution Approach 1:
The patent replaces the manual visual inspection system with an automated sensor-based detection system. The sensor detects whether tape is properly affixed by monitoring the unreeled state of the tape roll, eliminating the need for worker intervention while maintaining detection reliability and improving productivity.
2Productivity
If sensor-based automatic inspection is implemented assuming transparent tape, then productivity improves, but detection accuracy deteriorates when colored or patterned tape is used
Solution Approach 1:
The patent introduces an intermediary detection mechanism that monitors the unreeled state of the tape roll itself rather than directly detecting the tape on the box. By detecting whether the tape roll rotates and unreels during the affixing process, the system can identify affixing abnormalities regardless of the tape's color or pattern, maintaining both productivity and detection accuracy.
3Productivity
If sensor detects tape unreeled state to enable automatic inspection, then productivity improves and visual inspection is eliminated, but detection reliability may be compromised by false positives or negatives
Solution Approach 1:
The patent implements a feedback mechanism where the sensor continuously monitors the unreeled state of the tape roll and provides real-time information to the control system. The control system compares the detected unreeled state with the expected affixing process, enabling reliable automatic detection of abnormalities while maintaining high productivity through automated inspection.
Data Source
AI summary
A box-making apparatus includes an electronic controller assesses abnormalities in the affixing of tape on the basis of a timing at which a cardboard box passes a detection position Pd, and a timing at which a tape roll starts or stops an action of unreeling the tape. The electronic controller assesses abnormalities in the affixing of tape also when there is a discrepancy of at least a predetermined amount between the timing at which the cardboard box passes the detection position and the timing at which the tape roll starts or stops the action of unreeling the tape.