Fabric quality control assembly
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Solution Overview
Problem
Current fabric quality control methods are inadequate for early detection of defects such as lumps, needle runniness, stains, and hole formations during fabric production, leading to product casualties due to late diagnosis.
Innovation Solution
An assembly comprising a light source, light detection unit, and electronic processor unit that performs superficial scanning of fabric with high-resolution linear image acquisition and error indication, using multiple light sensors and a pointer light source to visually indicate defects, enabling real-time quality control during fabric movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional quality control methods are used, then the system is simple, but defect detection is delayed causing product casualties
Solution Approach 1:
The patent implements preliminary action by performing quality control measurements during the fabric production process itself, rather than after completion. The sensor system continuously monitors fabric parameters (such as lump, needle runniness, stains, and hole formations) in real-time, enabling early detection of defects before they become critical issues requiring product disposal.
Solution Approach 2:
The patent replaces traditional mechanical inspection methods with an automated sensor-based measurement system. Optical or electromagnetic sensors continuously scan the fabric during production, substituting manual or periodic mechanical checks with continuous automated monitoring, thereby eliminating detection delays and improving reliability.
2Measurement precision
If multiple sensors are used for comprehensive quality control, then measurement precision improves, but device complexity increases
Solution Approach 1:
The patent merges multiple sensor functions into an integrated quality control system. Rather than deploying separate independent inspection devices, the system combines multiple sensors (detecting different fabric parameters) into a single coordinated array that operates together during fabric production, achieving comprehensive measurement precision while managing device complexity through integration.
Solution Approach 2:
The sensor array is designed with multi-functionality to detect various fabric defects (lump, needle runniness, stains, hole formations) simultaneously using a unified system architecture. This universal approach allows a single device configuration to perform multiple measurement tasks, improving measurement precision across different defect types without proportionally increasing device complexity.
3Productivity
If continuous monitoring during fabric movement is implemented, then productivity is maintained, but measurement precision may be compromised due to motion
Solution Approach 1:
The patent implements dynamics by designing a sensor system that adapts to the moving fabric during production. The measurement system is configured to continuously track and measure fabric parameters while the material moves through the production line, rather than requiring the fabric to be stationary. This dynamic measurement capability maintains productivity by allowing continuous operation while achieving adequate measurement precision through real-time data acquisition during motion.
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
Ensures effective and timely detection of fabric defects, preventing product casualties by allowing for immediate action during production, with the ability to learn fabric patterns and report errors without stopping production.
Implementation Method 1
at least one light source configured to emit rays on the fabric, at least one light detection unit configured to detect the rays reflected from the said fabric
Data Source
AI summary
An assembly is provided for conducting quality control of objects in the form of linear movable fabric. The assembly includes at least one light source, at least one light detection unit, and an electronic processor unit. The fabric and the light detection unit include a drive means configured to make a linear relative movement with respect to each other, and the light detection unit is configured to receive a linear image at a given moment in a direction different from the direction of the linear relative movement.