Fabric Surface Characterization via Image Analysis

Solution Overview

Problem

Existing methods for characterizing the contact surface of papermaking fabrics are inaccurate, especially when the fabric becomes worn, as they rely on formulas that do not account for changes in knuckle and pocket dimensions, leading to unpredictable three-dimensional shaping of paper products.

Innovation Solution

A process using image analysis software to create a representation of the fabric's surface, generating an image, and drawing guidelines to outline knuckles and pockets, allowing for precise measurement of their sizes and locations, which can be used to calculate fabric properties such as knuckle density and pocket area.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If formulas based on yarn parameters are used to characterize fabric contact surface, then the characterization process is simple, but the accuracy of predicting paper product structure deteriorates

Engineering Contradiction:

Improvecharacterization process simplicityVSAvoidprediction accuracy of paper product structure

Core Design Contradiction:

Ease of manufactureVSMeasurement precision

Solution Approach 1:

The patent creates a digital copy (image) of the fabric contact surface that can be analyzed computationally. This digital representation captures the actual knuckle and pocket characteristics, allowing accurate measurement without physically measuring each feature. The image serves as a copy that preserves all geometric information while enabling precise digital analysis.

Inventive Principle:

Principle #26Copying

Solution Approach 2:

The patent replaces manual or mechanical measurement methods with image analysis and computer processing. Instead of physically measuring knuckle lengths and pocket areas, the system uses digital images processed by algorithms to automatically extract these parameters, significantly improving both accuracy and efficiency.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Productivity

If visual inspection is used to characterize fabric contact surface, then the method is simple and quick, but the ability to accurately determine knuckle sizes, pocket areas, and pocket depths deteriorates

Engineering Contradiction:

Improvecharacterization speedVSAvoidaccuracy of knuckle and pocket measurements

Core Design Contradiction:

ProductivityVSMeasurement precision

Solution Approach 1:

The patent creates a digital copy (image) of the fabric contact surface that can be analyzed computationally. This digital representation captures the actual knuckle and pocket characteristics, allowing accurate measurement without physically measuring each feature. The image serves as a copy that preserves all geometric information while enabling precise digital analysis.

Inventive Principle:

Principle #26Copying

Solution Approach 2:

The patent replaces manual or mechanical measurement methods with image analysis and computer processing. Instead of physically measuring knuckle lengths and pocket areas, the system uses digital images processed by algorithms to automatically extract these parameters, significantly improving both accuracy and efficiency.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If fabric wear is not accounted for in characterization formulas, then the initial characterization is accurate, but the characterization becomes inaccurate as the fabric wears over time

Engineering Contradiction:

Improveinitial characterization accuracyVSAvoidability to account for wear changes

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The patent performs characterization by capturing an image of the fabric contact surface before use, establishing a baseline digital representation. This preliminary action allows the system to record the initial state and track changes over time by comparing subsequent images against this baseline.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent enables continuous monitoring of fabric wear by repeatedly imaging the contact surface and comparing it to the initial state. This feedback mechanism tracks how knuckle lengths and pocket areas change over time, allowing the system to adjust predictions accordingly and maintain accuracy throughout the fabric's service life.

Inventive Principle:

Principle #23Feedback

Data Source

PatentEP3763875A1Process for determining features of a fabric

Publication Date: 2021.01.13 GPCP IP HOLDINGS LLC

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Figure 3A~3B

AI summary

Apparatuses, processes, and systems for determining features of a paper-making fabric. The apparatus, processes, and systems utilize a representation of a portion of a surface of the fabric, with the representation showing locations and sizes of knuckles and pockets in the surface of the fabric. An image of the portion of the fabric is generated based on the representation. Using the displayed image, an outline is drawn around at least one of the knuckles, and guidelines are drawn such that the guidelines pass through the center of the outlined knuckle, pass through the other knuckles, and form a shape that surrounds areas of the image that correspond to where the pockets are formed between the knuckles. With the outlined knuckle and guidelines, properties that affect the paper-making functionality of the fabric may be calculated.