Braille Tool Image Inspection for Wear and Sequence Accuracy
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Converting machines face challenges in accurately transferring braille lettering due to the need for frequent tool changes and wear, leading to confusion and reduced quality, especially in producing boxes with varying sizes and paper quality.
Innovation Solution
An inspection system that uses an image sensor to capture images of braille tools on embossing rollers, compares the actual braille sequence with a desired sequence stored in memory, and issues control signals to ensure accuracy and quality, also monitoring tool wear and surface quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple braille tools are used to match different artwork and box types, then adaptability is improved, but device complexity increases and operator confusion arises
Solution Approach 1:
The patent creates a digital copy (image) of the physical braille tool's protrusion pattern and stores it in memory. This digital copy serves as a reference for inspection, allowing the system to verify that the physical tool matches the required braille pattern without requiring multiple physical tools to be manually tracked and identified.
Solution Approach 2:
The inspection system provides feedback by comparing the actual braille pattern on the tool (captured by the sensor) against the desired pattern (stored in memory). This feedback mechanism allows the system to detect mismatches and alert operators, reducing confusion and ensuring correct tool usage without requiring extensive operator knowledge.
2Productivity
If braille tools are used continuously without replacement, then productivity is maintained, but manufacturing precision deteriorates due to tool wear
Solution Approach 1:
The system performs preliminary inspection of the braille tool before it is used to emboss boxes. By capturing an image of the tool's protrusion pattern and comparing it to the desired pattern, the system can detect wear or degradation before it affects product quality, allowing for timely tool replacement.
Solution Approach 2:
The inspection system provides continuous feedback on tool condition by comparing captured images against stored reference patterns. This feedback enables monitoring of tool wear over time and triggers replacement decisions based on actual condition rather than fixed schedules, maintaining both productivity and precision.
3Manufacturing precision
If braille tools are frequently replaced to maintain quality, then manufacturing precision is improved, but loss of time increases
Solution Approach 1:
The system performs preliminary inspection of the braille tool before it is used to emboss boxes. By capturing an image of the tool's protrusion pattern and comparing it to the desired pattern, the system can detect mismatches or wear before they affect product quality, allowing for timely tool replacement.
Solution Approach 2:
The inspection system provides feedback by comparing the actual braille pattern on the tool (captured by the sensor) against the desired pattern (stored in memory). This feedback mechanism allows the system to detect mismatches and alert operators, reducing confusion and ensuring correct tool usage without requiring extensive operator knowledge.
4Manufacturing precision
If inspection of braille tools is performed, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The patent creates a digital copy (image) of the physical braille tool's protrusion pattern and stores it in memory. This digital copy serves as a reference for inspection, allowing the system to verify that the physical tool matches the required braille pattern without requiring multiple physical tools to be manually tracked and identified.
Solution Approach 2:
The patent replaces manual visual inspection with an automated optical inspection system using a sensor to capture images of the braille tool's protrusions. This substitution of mechanical/manual inspection with optical detection simplifies the overall system while improving inspection consistency and precision.
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
Ensures accurate and high-quality braille transfer by preventing erroneous production, allowing for real-time validation of braille tools and anticipating tool replacement, thus maintaining production standards.
Implementation Method 1
an image sensor configured to capture at least one image of a first braille tool provided with embossing protrusions
Data Source
Figure 1
Figure 2a~2b
Figure 3a~3b
AI summary
The present invention relates to inspection system (46) for checking braillecharacters in a converting machine (1), the inspection system comprises an image sensor (48) configured to capture at least one image of a first braille tool (36) provided with embossing protrusions (40), a memory (52) and a control unit (51). The control unit is configured to determine an actual braille lettering sequence (Sa) from the at least one image and compare the actual braille lettering sequence to adesired braille lettering sequence stored in the memory.