Automated Inspection of Laminated Sheets Using Image Pattern Matching
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Solution Overview
Problem
In laminating processing, defects such as wrinkles, flaws, and air bubbles in the laminate film pressure-bonded to a recording medium require manual visual inspection, leading to significant time and labor costs.
Innovation Solution
An inspection apparatus and system that includes a hardware processor to automatically detect defects in laminated sheets by comparing original and read images, using pattern matching with pre-defined threshold values to identify and classify defects like wrinkles, flaws, and air bubbles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual visual inspection is used to detect defects in laminated sheets, then inspection accuracy can be maintained through human judgment, but operation time and labor costs increase significantly
Solution Approach 1:
The patent replaces the manual visual inspection system with an automated image processing system. The hardware processor captures images of the laminated sheet and automatically analyzes them to detect defects such as wrinkles, air bubbles, and foreign objects. This substitution eliminates the need for manual inspection while maintaining high detection accuracy through algorithmic image analysis.
Solution Approach 2:
The patent creates a digital copy (image) of the laminated sheet and performs inspection on this copy rather than requiring direct manual examination of the physical sheet. The image processing system captures the sheet's appearance and analyzes it computationally, enabling rapid automated inspection without physical contact or manual handling time.
2Adaptability or versatility
If manual visual inspection is used to detect defects in laminated sheets, then complex defect patterns can be identified through human expertise, but labor costs and operational effort increase
Solution Approach 1:
The patent replaces manual inspection expertise with an automated image processing system that can identify various defect types including wrinkles, air bubbles, and foreign objects. The system processes images automatically without requiring human physical effort or expertise, while maintaining the ability to detect and classify multiple defect patterns through computational analysis.
3Productivity
If automated image processing is implemented to detect defects, then inspection speed and productivity increase, but system complexity and initial investment increase
Solution Approach 1:
The patent implements a multi-functional inspection system where the image processing apparatus can detect various types of defects (wrinkles, air bubbles, foreign objects) using a single integrated system. The hardware processor performs multiple functions including image capture, processing, analysis, and defect classification, eliminating the need for multiple separate inspection devices and reducing overall system complexity.
4Productivity
If automated image processing is implemented to detect defects, then labor requirements decrease and operational efficiency improves, but measurement precision requirements increase
Solution Approach 1:
The patent adjusts processing parameters such as threshold values for defect detection, image processing algorithms, and analysis criteria to optimize the balance between automated inspection efficiency and detection precision. By carefully tuning these parameters, the system achieves high productivity while maintaining accurate defect identification capabilities.
Data Source
AI summary
An inspection apparatus that is capable of inspecting a sheet includes a hardware processor. The hardware processor detects a defect in laminating processing in a sheet that has been laminated with a film by the laminating processing.