Glue-Joint Failure Detection in Gypsum Board Production
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Solution Overview
Problem
Existing detection systems for glue-joint failure in gypsum board production cannot accurately identify the issue, are complex to install, and require significant setup, making it difficult to detect failures early and prevent defective products.
Innovation Solution
A system using optical detection means with a light emission part projecting laser light intersecting the conveyance direction of the forming belt and a light receiving part to measure light blocked by the edge portion, allowing for early detection of glue-joint failure by determining light quantity or ratio changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing detection systems are used for glue-joint failure, then detection capability is provided, but the systems are complex to install and require significant setup
Solution Approach 1:
The patent replaces complex mechanical detection systems with a simple optical detection system using a light receiver that measures light transmission through the gypsum board edge. This substitution maintains detection capability while dramatically reducing installation complexity and setup requirements.
Solution Approach 2:
The invention extracts the essential detection function from complex existing systems, isolating only the critical measurement of light transmission through the edge portion. This extraction eliminates unnecessary complexity while preserving the core detection capability for glue-joint failure.
2Reliability
If existing detection systems are used for glue-joint failure, then detection is provided, but early detection and prevention of defective products is difficult
Solution Approach 1:
The optical detection system is positioned to measure light transmission through the edge portion immediately after the forming stage, enabling early detection of glue-joint failure before the gypsum board proceeds through drying and cutting processes. This preliminary detection allows for timely prevention of defective products.
Solution Approach 2:
The patent uses light transmission through the edge portion as an intermediary indicator to detect glue-joint failure. This intermediary measurement provides accurate and timely detection of the bonding state between paper sheets and gypsum slurry, enabling early intervention.
3Ease of operation
If simple detection setup is used, then ease of installation is improved, but detection reliability may be compromised
Solution Approach 1:
The patent replaces complex mechanical detection apparatus with a simple optical sensor that measures light transmission. This substitution achieves both ease of installation and reliable detection by focusing on the fundamental optical property of the edge portion rather than requiring complex mechanical measurement systems.
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
Enables reliable early detection of glue-joint failure, reducing production losses by allowing for prompt adjustments and improving yield with a simple and easily deployable setup.
Implementation Method 1
a light emission part which is located on one side of the continuous layered formation and which projects a laser light toward an edge portion of the formation; a light receiving part which is opposed to the light emission part and located on the opposite side of the formation and which receives the laser light
Data Source
Figure 1(A)~1(C)
Figure 2
Figure 3
AI summary
[OBJECT] Glue-joint failure of upper and lower sheets of a gypsum board can be surely detected at an early stage with a simple arrangement, and detecting equipment systems can be relatively easily provided in positions of the gypsum board production line, spaced apart a distance in a conveyance direction. [SOLUTION] A light emission part (51, 52) is located on one side of a continuous layered formation (W). The light emission part projects a laser light (β) toward an edge portion of the formation. The laser light extends in a direction intersecting a conveyance direction of the forming belt (40). A light receiving part (53, 54), which receives the laser light of the light emission part, is opposed to the light emission part and located on the opposite side of the formation. The laser light passes through an area above an upper surface of the formation at least partially and is partially blocked by rising of the edge portion of the formation. The control device (70) determines occurrence of the glue-joint failure on the basis of whether the quantity of light received by the light receiving part is reduced by at least a predetermined value or a predetermined rate, and provides or gives a visual display or a warning of the occurrence of glue-joint failure by display means or warning means (71, 72).