Fabric Bag Production with Non-Contact Optical Defect Detection
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Solution Overview
Problem
Existing methods for producing bags from fabric material are inefficient in detecting and removing defective sections, leading to unsatisfactory quality and increased machine downtimes due to reliance on visual inspection and internal tools that can miss tissue defects and cause unnecessary processing interruptions.
Innovation Solution
A non-contact testing system using an illumination device and light detection, such as cameras or photocells, to identify defects before or after printing, with markings applied to defective areas for precise identification and separation within the processing machine, allowing only defect-free bags to be produced.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If visual inspection by operating personnel is used to detect defects, then the method is simple to implement, but the detection reliability is insufficient and cannot reliably detect tissue defects
Solution Approach 1:
The patent replaces manual visual inspection with an automated optical inspection system comprising illumination devices and light detection devices (cameras or photocells). This substitution eliminates human subjectivity and fatigue, providing consistent, reliable detection of tissue defects while maintaining operational simplicity through automated control.
Solution Approach 2:
The patent introduces an intermediary optical inspection system between the fabric material and the final product. This intermediary system uses light as a mediator to detect defects non-contactly, providing reliable defect identification without requiring direct human contact or complex mechanical inspection tools.
2Reliability
If internal tools are used to check fabric defects, then machine downtime increases due to processing interruptions, but the detection capability is improved
Solution Approach 1:
The patent implements continuous non-contact optical inspection throughout the processing line, eliminating the need to stop production for internal tool checks. The illumination and detection devices operate continuously alongside the fabric material flow, ensuring uninterrupted production while maintaining high defect detection capability.
Solution Approach 2:
The patent replaces mechanical internal inspection tools with non-contact optical sensing. This eliminates the need to physically insert tools into the processing machine, thereby preventing processing interruptions and maintaining continuous production flow while achieving reliable defect detection.
3Reliability
If internal tools are inserted into the fabric tube for inspection, then defect detection is enhanced, but the device complexity and risk of damage increase
Solution Approach 1:
The patent uses light as an intermediary medium to inspect fabric defects without physical contact. The illumination devices emit light through or reflected from the fabric material, and light detection devices capture the light patterns to identify defects, eliminating the need for complex mechanical internal tools that could damage the fabric tube.
Solution Approach 2:
The patent substitutes mechanical internal inspection tools with non-contact optical sensing systems. This replacement simplifies the inspection device by eliminating complex mechanical components that would need to be inserted into and potentially damage the fabric tube, while maintaining high defect detection accuracy through optical methods.
4Productivity
If defective sections are not properly identified and removed, then production continuity is maintained, but product quality deteriorates
Solution Approach 1:
The patent implements a feedback system where the light detection devices continuously monitor the fabric material and provide real-time defect information to the control system. This feedback enables automatic identification and marking of defective sections, allowing precise removal of only the defective portions while maintaining continuous production of quality bags.
Solution Approach 2:
The patent performs preliminary defect identification and marking before the fabric material proceeds to bag production. By detecting and marking defective sections in advance using optical inspection, the system enables selective removal of defective portions without interrupting the overall production flow, ensuring both productivity and quality.
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 significantly improves the detection rate of fabric defects, ensures only high-quality bags are produced, reduces machine downtime, and simplifies the removal of defective sections, enhancing overall product quality and efficiency.
Implementation Method 1
which illuminates the fabric material in the product flow direction with light
Implementation Method 2
at least one light detection device is provided which, facing the illumination device, detects light that has passed through the fabric material
Data Source
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AI summary
The invention describes a method for producing bags from fabric material which comprises small stretched plastic tapes. The method comprises the following steps of: - coating the fabric material, - printing on the fabric material, - checking the fabric material at least for flaws in the fabric using a testing device, - producing tube portions from the fabric material and forming bottoms onto the ends of the tube portions in order to produce bags in a processing machine, - discharging a tube portion or a bag from the production flow if the fabric material of this tube portion or this bag contains a flaw. The fabric material is checked for flaws in a contactless manner.