Corrugated Board Order Change Detection Using Printed Image Recognition
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Solution Overview
Problem
Existing systems for processing small batches or orders of corrugated sheets are complex and expensive, requiring the printing of specific markers on the corrugated board web to control the production line.
Innovation Solution
A plant for manufacturing corrugated board sheets that uses the images printed on the corrugated board web to automate and simplify the transition between orders, eliminating the need for printed markers by employing a visual inspection system to read and recognize the images and adjust the production settings accordingly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If markers containing order information are printed on the corrugated board web to enable automatic detection and setting of cutting and scoring members, then the productivity and automation of small batch production is improved, but the device complexity increases due to the need for printing systems and visual inspection systems
Solution Approach 1:
The corrugated board web itself serves as the information carrier by using its printed decorative images to encode order information. The visual inspection system detects these existing images without requiring separate marker printing systems, making the production line self-sufficient for order identification
Solution Approach 2:
The printed images on the corrugated board web serve dual functions: their original decorative/marketing purpose and the additional function of encoding order information for automated detection. This eliminates the need for dedicated marker systems while maintaining productivity benefits
2Measurement precision
If specific markers are printed on the corrugated board web to control production line settings, then the measurement precision of order detection is improved, but the manufacturing cost increases due to marker printing requirements
Solution Approach 1:
The production line uses the corrugated board web's own printed images for order detection, eliminating the need for separate marker printing processes and associated costs while maintaining detection precision
Solution Approach 2:
The visual inspection system reads and interprets the existing printed images on the corrugated board web, using these copies of order information already present in the decorative printing to control production settings without additional marker printing costs
3Adaptability or versatility
If the production line is configured to read printed images on the corrugated board web for order detection, then the adaptability to different orders is improved, but the device complexity increases due to image recognition system requirements
Solution Approach 1:
The visual inspection system is designed to read various printed images on the corrugated board web that serve as order identifiers, enabling the system to adapt to different production orders using the existing decorative printing infrastructure
Solution Approach 2:
The patent replaces mechanical marker printing and physical marker placement systems with an optical image recognition system that reads printed images, reducing mechanical complexity while improving adaptability to different order configurations
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 solution allows for smoother and more efficient management of production lines, enabling the use of rolls from any origin and reducing the complexity and cost associated with marker-based systems, while maintaining accurate production control.
Implementation Method 1
employing a visual inspection system to read and recognize the images
Data Source
AI summary
The plant comprises includes a visual inspection system provided with one or more vision units. The vision units detect and recognize, through adequate electronic processing, the images printed on at least one face of the corrugated board web. Based on the image recognition, the control system recovers, from a lookup table, information for setting the converting line to produce the subsequent order of sheets.