Fiducial Mark Registration for Web Anomaly Synchronization
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Inspection systems for continuously moving webs face challenges in processing high data rates and maintaining accurate defect detection, particularly in manufacturing processes where webs undergo multi-stage converting processes, leading to loss of spatial synchronization of anomaly data.
Innovation Solution
The system employs fiducial marks to maintain spatial synchronization of anomaly data by registering position information and re-printing fiducial marks on slit rolls, allowing for updated position monitoring and re-registration of anomaly data across different stages of web conversion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the web undergoes multi-stage converting processes including slitting and re-rolling, then productivity and manufacturing efficiency are improved, but spatial synchronization of anomaly data is lost
Solution Approach 1:
Fiducial marks are printed on the web at predetermined intervals before the converting processes begin. This preliminary action establishes a reference framework that will survive subsequent slitting and re-rolling operations, enabling later reconstruction of spatial relationships without requiring real-time data processing during conversion.
Solution Approach 2:
The system creates a digital copy of the fiducial mark positions and anomaly locations that can be stored and processed independently from the physical web. This digital replica allows for mathematical transformation of coordinates to maintain spatial synchronization even as the physical web undergoes multiple conversion stages.
2Productivity
If high data acquisition rates are used to keep up with manufacturing speeds, then productivity is improved, but data processing complexity increases
Solution Approach 1:
The system extracts only the essential spatial reference information from fiducial marks rather than processing all anomaly data at full manufacturing speed. By separating the reference framework (fiducial marks) from the detailed anomaly data, the system reduces processing complexity while maintaining the ability to synchronize data at high speeds.
3Measurement precision
If fiducial marks are used to maintain spatial synchronization, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The system changes the parameter of spatial reference from continuous complex coordinates to discrete fiducial mark positions. By using predetermined, simple-to-detect fiducial marks as reference points, the system achieves high measurement precision through straightforward position detection and mathematical coordinate transformation rather than complex continuous measurement systems.
Data Source
AI summary
Techniques are described for maintaining synchronization of inspection data when a web roll is converted into intermediate smaller rolls prior to cutting the web into individual parts. A system comprises a database that stores anomaly data acquired from a manufactured web. The anomaly data specifies positions anomalies within a manufactured web relative to a set of fiducial marks on the manufactured web. A conversion processing line comprises a fiducial mark reader to output position information for the set of fiducial marks on the manufactured web, a slitter that cuts the manufactured web into slit rolls, and a fiducial mark printer to print a set of fiducial marks on each slit roll. A position monitoring system maintains spatial synchronization of the anomaly data by computing an updated position for the anomalies relative to the set of fiducial marks printed on the slit rolls.