Filter Rod Embossing Quality Control via Optical Feedback
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Solution Overview
Problem
Existing filter rod manufacturing machines in the tobacco processing industry lack effective quality monitoring and control of the embossed structure on wrapping material, leading to inconsistent quality of CP filter rods.
Innovation Solution
A method involving continuous conveying of wrapping material through an embossing device to form a longitudinal embossed structure, followed by optical image data capture and processing to determine the quality and position of the embossing, which regulates the manufacturing machine's operation to ensure high-quality filter rod production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If optical image data capture and processing is implemented to monitor embossing quality, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The patent implements a feedback mechanism where optical image data is captured during the embossing process, processed to determine embossing quality, and used to regulate the manufacturing machine operation. This closed-loop feedback system continuously monitors and adjusts the embossing process to maintain manufacturing precision.
Solution Approach 2:
The patent replaces manual or mechanical quality inspection methods with optical image capture and automated processing. This substitution of mechanical inspection with optical-digital systems enables precise quality monitoring while reducing the need for complex mechanical measurement devices.
2Manufacturing precision
If real-time quality monitoring and regulation is implemented, then product quality is improved, but productivity is reduced
Solution Approach 1:
The patent maintains continuous conveying of the wrapping material strip through the embossing device, ensuring that the production process does not stop for quality inspections. The optical monitoring and regulation occur in real-time during continuous operation, preserving productivity while ensuring quality.
Solution Approach 2:
The real-time feedback system allows for immediate regulation of embossing parameters during continuous production, preventing defects rather than requiring post-production rejection or rework. This maintains both high quality and continuous production flow.
3Measurement precision
If optical image data processing is added to the manufacturing machine, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The patent replaces complex mechanical measurement systems with optical image capture and digital processing. This substitution provides high measurement precision for embossing position and quality while using lighter, more compact optical components compared to mechanical measurement devices.
Solution Approach 2:
The patent creates optical copies (images) of the embossed structure for analysis. These digital copies can be processed, stored, and analyzed without physically touching or interfering with the production process, enabling precise measurement without adding complex physical measurement apparatus.
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 enhances the quality and consistency of filter rods by real-time monitoring and adjustment of embossing parameters, improving the manufacturing process efficiency and product quality.
Implementation Method 1
capturing, in particular digitized, image data of the rod or the filter rod
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
The method according to the invention provides for the embossing of a first wrapping material strip (33) and the acquisition of, in particular, digitized image data (80) of a strand (21) formed from the embossed first wrapping material strip or of a rod-shaped article cut from this strand, wherein the quality and/or position of the embossing structure is determined on the basis of the image data and the operation of the manufacturing machine is controlled or regulated on the basis of the quality and/or position of the embossing structure. The manufacturing machine (1) according to the invention has a device (23) for processing a first wrapping material strip (33), wherein the manufacturing machine (1) has a strand forming device (16, 17) in which the first wrapping material strip (33) is wound or can be wound around a strand material during longitudinal axial conveying (22) of the strand material, wherein an image data acquisition device (30) is provided.image data (80) of the strand (21) wrapped with the first wrapping material strip (33) can be recorded or are recorded, wherein an image data processing device (60, 91, 94) is provided by means of which the quality and/or the position of an embossed structure applied to the first wrapping material strip (33) can be determined or is determined, and wherein a control and/or regulating device (61, 96) is provided which, based on the determined quality and/or position of the embossed structure, adjusts control and/or regulating parameters during the operation of the manufacturing machine (1).