Cigarette Circumferential Defect Detection via Rotating Vision System
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Solution Overview
Problem
Current off-line detection methods for cigarette appearance quality defects, particularly yellow stains, are inefficient and prone to errors due to manual visual inspection, which cannot keep pace with high-speed production and fail to provide quantitative data for timely quality feedback.
Innovation Solution
A device comprising a mechanical system with rotating rollers and a vision system that allows for 360° detection of cigarette circumferential appearance quality, enabling continuous and quantitative analysis of defects, including yellow stains, punctures, wrinkles, and clipping, with a control system for sorting and data processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If manual visual detection is used to detect cigarette appearance quality, then the detection method is simple and requires no special equipment, but the detection efficiency is low and cannot keep pace with high-speed production
Solution Approach 1:
The patent replaces manual visual detection with an automated image processing system that uses cameras to capture cigarette images and software to analyze appearance defects. This substitution of mechanical/manual inspection with automated optical-mechanical systems resolves the contradiction by maintaining detection capability while dramatically improving efficiency to match high-speed production rates.
Solution Approach 2:
The detection system is designed to be self-operating, automatically capturing images, processing data, and generating detection results without requiring manual intervention. The system performs self-service detection, eliminating the need for operators while maintaining continuous operation at production line speeds.
2Device complexity
If manual visual detection is used, then no special equipment is needed, but detection errors increase and quantitative data cannot be obtained
Solution Approach 1:
The patent replaces subjective manual visual assessment with objective image processing technology. Cameras capture high-resolution images and software algorithms automatically analyze defect characteristics, eliminating human error and providing precise, quantifiable measurement data for each cigarette inspected.
Solution Approach 2:
The system creates digital copies (images) of each cigarette's appearance, allowing for precise analysis and measurement without physical contact. These digital replicas enable accurate detection of defect dimensions, areas, and characteristics that cannot be reliably measured by manual inspection.
3Ease of operation
If statistical sampling is used for manual detection, then the detection process is simple, but misjudgment occurs due to subjective factors and unstable detection standards
Solution Approach 1:
The patent replaces subjective human judgment with objective algorithm-based detection. The image processing software applies consistent detection criteria to every cigarette, eliminating variability between different operators and ensuring reliable, repeatable results across all inspections.
Solution Approach 2:
The system provides immediate feedback for each cigarette inspection, automatically classifying defects and providing real-time quality data. This feedback mechanism ensures consistent application of detection standards and allows for continuous monitoring of quality trends.
4Measurement precision
If on-line visual detection system is used to detect entire circumference, then complete detection is achieved, but multiple systems are required increasing investment
Solution Approach 1:
The patent uses a rotating cigarette holder that rotates cigarettes 360 degrees while a single camera captures images from different angles. This dimensional approach allows one camera to achieve what would otherwise require multiple fixed cameras, reducing system complexity and investment while maintaining complete circumferential detection capability.
Data Source
AI summary
A device for off-line detection of circumferential appearance quality of cigarettes includes a mechanical system, a vision system and a control system, where the mechanical system includes a hopper, a feed roller, an auto-rotating roller, an upper chute and a lower chute. A method for off-line detection of circumferential appearance quality of cigarettes by using the above device is further provided. The present disclosure can achieve detection without omission to obtain accurate and quantifiable detection results, and has high processing efficiency.