Carrier Strip Defect Removal via Offset Detachment
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Solution Overview
Problem
Existing methods for producing defect-free carrier webs often require reducing carrier web speed to ensure reliable operation, as they involve selective detachment and transfer processes that can be inefficient.
Innovation Solution
A device and method for continuously separating defective components from a carrier web using a control device, receiving device, detaching device, and selection device, allowing for components to be detached and repositioned without reducing web speed, utilizing a detachable connection and controlled force to differentiate between faulty and fault-free components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If selective detachment and transfer processes are used to produce defect-free carrier webs, then manufacturing precision is improved, but productivity deteriorates due to reduced carrier web speed
Solution Approach 1:
The carrier web is divided into individual components that can be independently detached and repositioned. Each component can be selectively removed from the carrier web without affecting the stability of other components, enabling parallel processing and maintaining high web speed while achieving defect-free production.
Solution Approach 2:
Components are pre-detached from the carrier web before the selection process. This preliminary detachment allows the selection device to simply redirect already-loosened components rather than performing both detachment and selection sequentially, eliminating the speed reduction normally required for reliable selective detachment.
2Manufacturing precision
If selective detachment processes are implemented to remove defective components, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The detachment device and selection device are merged into a single integrated system. The detachment device performs both the loosening of components and their redirection for defective ones, combining multiple functions into one device and reducing overall system complexity while maintaining defect detection and removal capabilities.
Solution Approach 2:
The detachment device is designed to perform multiple functions: it detaches all components from the carrier web, identifies which ones are defective through the selection device, and redirects only the defective components while allowing good components to remain on the carrier web. This multi-functionality reduces the need for separate dedicated devices for each operation.
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 the production of defect-free carrier webs at high speeds by allowing continuous detachment and repositioning of components without the need for selective detachment processes, thereby increasing throughput and maintaining reliable operation.
Implementation Method 1
An adhesive layer can be applied to the components and/or to the carrier web, which enables a detachable connection of carrier web and component.
Implementation Method 2
If the components are electronic components with a memory that can be read without contact, the serial number of the electronic component can be checked, for example, or specific memory contents can be checked via a radio interface.
Implementation Method 3
Optical inspection by cameras in conjunction with image processing algorithms can also be used to identify a defective component.
Implementation Method 4
at least one detaching device, which at least partially detaches each component from the carrier web and reapplies it to the carrier web offset in relation to a previous position
Implementation Method 5
a faulty, partially detached component is subjected to a force for selection in such a way that it is deflected in the direction of the takeover device
Data Source
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AI summary
The invention relates to a device (1) for continuously selecting defective components (2) from a certain amount of components (2) which are arranged in a detachable manner on a carrier strip (3) in at least one continuous row, and a device (80) and method for continuously producing a carrier strip (3), which is void of defects, from a carrier strip (3) whereon components (2) are arranged in at least one continuous row, and which comprises defective components (2) and components which are void of defects (2). Said device (1) for continuously selecting defective components (2) comprises a control device (10) which is used to determine defective components, a transfer device (20) which is used to transfer selected, defective components (2), at least one separation device (30, 31, 32), which at least partially separates each component (2) from the carrier strip (3) and replaces it in an offset manner in relation to the preceding position on the carrier strip (3), and at least one selection device (40), which selects a component (2) which is determined as defective by the control device (10) and at least partially separates it from the carrier strip (3) in such a manner that said component is removed by the transfer device (20). Said device can be used, for example, in the production of labels (smart labels).