Defect Detection for Moving Fibrous Sheets Using Dual Arrays
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Solution Overview
Problem
Current defect detection systems for nonwoven textiles fail to accurately identify defects along the width of the material, leading to unnecessary rejection of entire rolls due to their pliable nature and increasing production speeds, which complicates precise defect location and flexible production adjustments.
Innovation Solution
A method involving a primary detection array that scans the textile shortly after formation and a secondary detection array positioned before the cutting station, allowing for precise defect identification and assessment, with the secondary array confirming defect locations and reducing waste by only discarding affected sections rather than entire rolls.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single detection array is used to scan the textile, then the system structure is simple, but the defect location precision along the width is insufficient leading to unnecessary rejection of entire rolls
Solution Approach 1:
The detection system is divided into multiple independent detection arrays (first detection array and second detection array) positioned at different locations along the production line. Each array independently scans the textile and identifies defects, with their results later correlated to achieve precise defect location mapping along the width, thereby avoiding unnecessary rejection of entire rolls.
2Productivity
If the textile travels faster through the production line to increase output, then productivity increases, but the time available for defect detection and production adjustments decreases
Solution Approach 1:
The first detection array is positioned to scan the textile early in the production process, before the material progresses further along the line. This preliminary detection allows for early identification of defects and timely production adjustments, preventing waste of subsequent material even at high production speeds.
Solution Approach 2:
The system continuously monitors defects detected by both arrays and provides real-time feedback to control production parameters. This closed-loop feedback mechanism enables dynamic adjustment of production settings based on detected defects, maintaining high productivity while ensuring quality control.
3Reliability
If the entire width of the textile is rejected due to a defect, then product quality is maintained, but material waste increases
Solution Approach 1:
The system applies different quality assessment criteria to different横向 positions of the textile based on defect location. By precisely mapping defect positions using multiple detection arrays, the system can identify and reject only the specific local areas containing defects while allowing defect-free sections to proceed, thereby maintaining product quality while minimizing material waste.
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 enables flexible production adjustments and reduces material waste by accurately pinpointing defects along the width of the textile, ensuring only affected sections are discarded, thereby improving production efficiency and maintaining product quality.
Implementation Method 1
Another method has the light source and the detection camera located on the same side of the material and the detection camera scans the reflected light
Implementation Method 2
one method has the light source located on one side of the material with the detection camera located on the other side
Data Source
AI summary
A defect detection method on a moving sheet of pliable fibrous material. The primary detection array is used to scan the moving sheet of fibrous material in at least one primary detection area, which fibers, after falling onto the moving belt, enter after a time shorter than 15 minutes. The secondary detection array scans the sheet of fibrous material in at least one secondary detection area, which the fibers, after falling on the carrying belt, reach later than the primary detection area, whereupon the information about the identified defects is sent to the assessment system, where, on the basis of information about at least some defects identified by the primary detection array, an area of the sheet of fibrous material is determined for which an assessment of defects identified by the secondary detection array will be performed.