Fabric Cutting Video Inspection With Automated Defect Sorting
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Solution Overview
Problem
Current template-based evaluation methods for textile cutting in the automotive industry are prone to significant errors and are slow, leading to faulty parts being introduced into production, which can compromise safety and result in costly rework or safety hazards.
Innovation Solution
An automated video inspection system that uses computer techniques for real-time image processing, part identification, and automatic evaluation of dimensions, combined with a modular pick-up and gripping assembly and RFID-enabled traceability, to rapidly and accurately sort and collect cut textile pieces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If template-based evaluation method is used for textile cutting inspection, then the inspection process is simple to implement, but the measurement precision and reliability are significantly poor leading to faulty parts
Solution Approach 1:
The patent replaces manual template-based measurement with an automated vision system using cameras and image processing software. The system captures images of cut textile parts, automatically identifies key points, and calculates dimensions through coordinate transformation and mathematical computation, eliminating the need for physical templates and manual measurement while achieving high precision.
Solution Approach 2:
The patent creates a digital copy of the part geometry by capturing images with cameras and processing them through software. The system generates virtual models and coordinate data that replicate the physical part's dimensions, allowing for accurate digital measurement and comparison without physical contact, thereby achieving high measurement precision with automated equipment.
2Productivity
If template-based evaluation method is used, then the inspection process is easy to operate, but the productivity is extremely slow depending on the number of measurement dimensions
Solution Approach 1:
The patent implements continuous automated inspection where cameras continuously capture images of parts moving on the conveyor belt. The system processes multiple images in sequence without interruption, performing real-time dimensional measurement and quality assessment, thereby dramatically increasing inspection speed and eliminating the time loss associated with manual measurement of each dimension.
Solution Approach 2:
The patent enables the inspection system to automatically perform all measurement tasks without human intervention. The software autonomously identifies part features, calculates dimensions, compares them against specifications, and generates inspection reports, making the system self-sufficient and eliminating the time-consuming manual operations of traditional template-based methods.
3Reliability
If template-based evaluation is used, then the equipment cost is low, but the reliability is poor resulting in faulty parts being introduced into production
Solution Approach 1:
The patent replaces error-prone manual template-based evaluation with automated vision systems and software algorithms. The system uses digital image processing and coordinate transformation to objectively measure dimensions, eliminating human factors such as subjective judgment, template alignment errors, and measurement inconsistencies, thereby significantly improving quality assurance reliability.
Solution Approach 2:
The patent implements a feedback mechanism where the inspection system continuously monitors part dimensions, compares measurements against specified tolerances, and provides immediate feedback on pass/fail status. This closed-loop system ensures that only parts meeting quality standards are approved, preventing faulty parts from entering production while maintaining automated complexity management through systematic control.
Data Source
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AI summary
The invention relates to a system for video inspection of the fabric cutting operation, video inspection of the fabric prior to cutting and selective collection of the finished products mounted on an automatic laser/knife cutting coordinated cutting equipment, wherein, the textile material unwound and conveyed by means of a conveyor (5) is passed through a first textile material video inspection subsystem (4) which transmits information to a defect marking assembly (6) arranged at the top of the conveyor (5) downstream of the cutting machine (7) and the cutting area, a second textile material cutting operoptimisationation video inspection subsystem (9) is installed after video inspections and marking of textile material defects and cutting defects with a defect marking assembly (10), the cut pieces (8) are transported to a modular pick-up and gripping assembly (12) and then toptimisationo a pulling system (14) for the cut piece (8), to be subsequently transported to collection crates (15) or to a waste material collection assembly (13), the collection crates (15) being part of a storage subsystem (16), the cut pieces of textile material being placed underneath a storage subsystem (17) in waiting crates, the positioning of the collection crates (15) with cut pieces on each level being performed by a crate handling device (18), and the level change being performed by a crate transfer device between levels/crate lift (19s , 19d), a crate positioning and locking device on the lift (20) checking and correcting the position of each crate before it is taken over by a crate handling device (18).