Hose Component Positioning via Image Feedback
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Solution Overview
Problem
The existing methods for positioning valve or cover sheets relative to hose components in bag production are time-consuming and result in significant product rejects due to large geometric product tolerances, leading to interruptions in production and scrap bags.
Innovation Solution
A method involving the recording of images during bag production to determine deviations in the positions of valve or cover sheets, prints, coatings, and embossings relative to reference points, with calculated deviations used to adjust the positions of transport devices and application units in real-time, allowing for continuous production without interrupting the process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional adjustment methods are used at the beginning of production, then the positioning can be initially set, but the adjustment process is time-consuming and requires production interruption
Solution Approach 1:
The patent implements a feedback mechanism where images of hose pieces and applied components are captured during production, position deviations are measured and calculated, and the transport devices are automatically adjusted in real-time. This closed-loop feedback system eliminates the need for time-consuming initial adjustments while maintaining high positioning precision throughout production.
Solution Approach 2:
The system performs preliminary measurement of position deviations using image processing before the actual positioning error affects product quality. By measuring and calculating deviations in advance during the production process, the system can correct positions proactively rather than reactively, eliminating production interruptions.
2Manufacturing precision
If traditional adjustment methods are used, then initial positioning can be established, but production must be interrupted for re-adjustment when tolerances are exceeded
Solution Approach 1:
The feedback mechanism continuously monitors position deviations during production and automatically adjusts transport devices in real-time. This eliminates the need to interrupt production for re-adjustment, as the system self-corrects deviations within tolerance ranges without stopping the production line.
Solution Approach 2:
The system transitions from static initial adjustment to dynamic real-time adjustment. The transport devices are continuously adapted during production based on measured deviations, allowing the system to respond to variations in hose piece positioning without interrupting the production flow.
3Productivity
If geometric product tolerances are large, then production can proceed without frequent adjustments, but the proportion of rejects increases significantly
Solution Approach 1:
The feedback system measures actual positions of valve labels, bottom cover sheets, and other components relative to hose piece reference points, calculates deviations, and automatically adjusts transport devices. This continuous correction reduces geometric product tolerances and minimizes scrap while maintaining production continuity.
Solution Approach 2:
The patent replaces manual mechanical adjustment with automated image processing and computational measurement. By using optical measurement systems and computer-based deviation calculation, the system achieves more precise positioning control than traditional mechanical adjustment methods, reducing both scrap and adjustment interruptions.
4Manufacturing precision
If multiple transport devices are coordinated manually, then initial positioning can be established, but the coordination is complex and time-consuming
Solution Approach 1:
The system captures images of multiple hose pieces and applied components, automatically measures positions of all components relative to reference points, calculates deviations for each transport device, and coordinates adjustments across all devices simultaneously. This automated feedback system simplifies the coordination of multiple transport devices while maintaining precise positioning.
Solution Approach 2:
The image processing system serves multiple functions: it measures positions of different components (valve labels, bottom cover sheets), determines deviations for different transport devices, and coordinates adjustments across the entire production line. This multi-functional approach reduces the overall complexity of coordinating multiple devices.
Data Source
Figure 1a~1b
Figure 2
AI summary
The invention describes a method for correctly aligning valve or cover sheet labels, imprints, coatings and/or embossings on or into components of hose sections, comprising the following process steps: a) taking images of the components of several hose sections with valve or cover sheet labels, imprints, coatings and/or embossings applied or inserted, b) determining the positions of valve or cover sheet labels, imprints, coatings and/or embossings relative to a reference point of the components of the hose sections, c) calculating the deviation of the determined position from the target position, d) calculating an average deviation of the determined position from the target position across several determined positions, and e) changing the positions of the valve or cover sheet labels and the components of the hose sections by the value of the average deviation.