Corrugated Cardboard Gluing Defect Detection via Optical Imaging
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Solution Overview
Problem
Current systems for detecting gluing defects in corrugated cardboard production plants are inefficient and unable to differentiate between various types of defects, limiting their functionality and preventing automatic management of the production line.
Innovation Solution
A plant equipped with a single facer, corrugating rollers, a pressing member, unwinding devices, a series of hot plates, and a viewing system comprising video cameras and an image processing unit to detect and track gluing defects, allowing for automatic removal of defective portions and adjustment of operating parameters to prevent defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If ultrasonic sensors are used to detect gluing defects, then the detection system can be implemented, but the system is not efficient and cannot differentiate among different types of gluing defects
Solution Approach 1:
The patent replaces ultrasonic sensors with an optical detection system consisting of a video camera and image processing unit. This substitution enables visual capture and digital analysis of gluing defects, providing both high detection accuracy and the capability to differentiate among various defect types through image analysis algorithms.
Solution Approach 2:
The patent changes the detection parameter from ultrasonic wave reflection to optical image capture. By using a video camera to capture images of the corrugated cardboard and applying image processing techniques, the system achieves superior defect differentiation capability while maintaining high detection reliability.
2Reliability
If known optical detection systems are used, then gluing defects can be detected, but the systems have limited functionalities and do not allow automatic management of the production line
Solution Approach 1:
The patent implements a feedback mechanism where the image processing unit continuously monitors gluing defects and communicates with the central control unit. The system provides real-time feedback on defect detection results, enabling automatic adjustment of production parameters and triggering of removal mechanisms, thus achieving automatic production line management.
Solution Approach 2:
The patent creates a multi-functional detection system that not only detects gluing defects but also classifies defect types, provides real-time alerts, triggers automatic removal mechanisms, and enables production parameter adjustments. This universal system handles multiple tasks that were previously required by separate manual processes.
3Reliability
If a video camera and image processing unit are added to the plant, then gluing defects can be effectively identified and classified, but the device complexity increases
Solution Approach 1:
The patent introduces an image processing unit as an intermediary between the video camera and the central control unit. This intermediary component handles the complex tasks of image analysis and defect classification, allowing the video camera to remain a relatively simple device while achieving high identification accuracy through sophisticated processing algorithms.
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 system effectively identifies and classifies gluing defects, enabling automatic or semi-automatic modification of production parameters to reduce or eliminate defects, improving the efficiency and accuracy of corrugated cardboard production.
Implementation Method 1
a first video camera arranged along the cardboard feeding path, configured and arranged to acquire images of a first face of the cardboard
Implementation Method 2
an image processing unit, which interfaces the first video camera and processes images acquired by the first video camera and detects defects in cardboard gluing or corrugating
Implementation Method 3
a first corrugating roller and a second corrugating roller cooperating with each other to corrugate a first cardboard sheet
Implementation Method 4
a pressing member to glue the first cardboard sheet, corrugated by means of the first corrugating roller and of the second corrugating roller, to a second smooth cardboard sheet
Implementation Method 5
The single-faced corrugated cardboard is fed, together with a third smooth cardboard sheet, to a series of hot plates where the single-faced corrugated cardboard is glued to the third smooth cardboard sheet
Data Source
Figure 1(A)~1(B)
Figure 1(C)~1(D)
Figure 2~3A
AI summary
The plant comprises a single facer (21) for the production of a corrugated board (NS). Video cameras (71, 73) detect any gluing defects or other defects of the corrugated cardboard. An image processing unit (75) and a central control unit (77) provide information about the detected defects and can act on one or more operating parameters of the plant.