Matrix Scanning for Cigarette Integrity Defect Detection
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Solution Overview
Problem
Current quality control systems for tobacco products are prone to 'false positives' due to airborne foreign matter, leading to unnecessary rejection of sound products, and require multiple cameras and complex systems to maintain high production rates, which increases costs and complexity.
Innovation Solution
A single matrix-type scanning device captures images of tobacco products from different angles, allowing for reliable quality control by comparing statistical parameters of selected regions of interest from multiple scans, reducing the need for multiple cameras and complex systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If multiple cameras are used to perform multiple scans per cigarette, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The patent merges the functions of multiple cameras into a single matrix-type scanning device that can capture multiple scan lines simultaneously. This single device performs what previously required multiple separate cameras, thereby maintaining measurement precision while reducing device complexity and the number of components required
Solution Approach 2:
The patent transitions from using multiple linear cameras arranged in one dimension to a single matrix-type scanning device that captures two-dimensional image data. This dimensional change allows the single device to perform multiple scans across different regions of the cigarette simultaneously, achieving the same quality control precision with fewer components
2Productivity
If multiple cameras are deployed to maintain high production rates, then productivity is maintained, but device complexity and costs increase
Solution Approach 1:
The patent combines the scanning functions of multiple cameras into a single matrix-type scanning device that can capture multiple scan lines across different regions of the cigarette simultaneously. This merging maintains the ability to inspect multiple areas in parallel, preserving productivity while reducing the number of separate camera units required
Solution Approach 2:
The matrix-type scanning device continuously captures image data across multiple scan lines as the cigarette moves through the inspection area. This continuous simultaneous scanning of multiple regions maintains the high-speed inspection capability needed for high production rates without requiring sequential scanning that would slow down productivity
3Device complexity
If a single camera performs multiple sequential scans, then device complexity is reduced, but productivity decreases due to required pausing
Solution Approach 1:
The patent employs a matrix-type scanning device that captures two-dimensional image data with multiple scan lines simultaneously, rather than using a single linear camera that would need to perform sequential scans. This dimensional change enables the single device to inspect multiple regions of the cigarette at the same time, maintaining high productivity while using simplified single-device architecture
Solution Approach 2:
The patent merges the functionality of multiple sequential scanning operations into a single simultaneous multi-line scanning operation using a matrix-type device. This allows the system to perform what would otherwise require multiple sequential scans in a single simultaneous operation, eliminating the need for pausing while maintaining device simplicity
4Measurement precision
If conventional optical scanning is used in dust-laden environments, then quality control can be performed, but false positives increase due to airborne foreign matter
Solution Approach 1:
The patent divides the cigarette surface into multiple distinct scan lines or regions that are scanned simultaneously by the matrix-type device. By segmenting the inspection into multiple independent scan lines, the system can identify when a defect appears in only one scan line (likely a foreign particle) versus defects that appear consistently across multiple scan lines (actual product defects), thereby reducing false positives in dust-laden environments
Solution Approach 2:
The system uses feedback from comparing results across multiple simultaneous scan lines to distinguish between actual defects and foreign particles. When the same anomaly appears across multiple scan lines, it is identified as a real defect; when it appears in only one scan line, it is likely a foreign particle causing a false positive, allowing the system to filter out erroneous detections
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
This approach minimizes false positives by accurately distinguishing between product defects and foreign matter, enabling efficient and reliable quality control at high production rates with reduced system complexity and costs.
Implementation Method 1
a matrix-type scanning device by means of which to capture a first image A1 of a single tobacco product 2a, and thereafter a second image A2 of the selfsame tobacco product 2a
Data Source
Figure 1
Figure 2~2a
Figure 3
AI summary
The external integrity of tobacco products, typically cigarettes, is monitored by a method that includes the steps of scanning a first image (A1) of a single tobacco product (2a); selecting a first region of interest (ROI-1) located within and smaller than the first image (A1), in which the single product (2a) is shown; sending the first region of interest (ROI-1) to an electronic processing unit (13); scanning a second image (A2) of the single tobacco product (2a), subsequent to the step of scanning the first image (A1); selecting a second region of interest (ROI-2) located within and smaller than the second image (A2), in which the single product (2a) is shown; sending the second region of interest (ROI-2) to the electronic processing unit (13); comparing the first and second regions of interest (ROI-1, ROI-2), by means of the processing unit (13), with one or more references; generating a notification signal (16), based on the result of the comparison, to indicate an impairment in the external integrity of the tobacco product (2a) shown in the first and second regions of interest (ROI-1, ROI-2).