Laser 3D Embossing Inspection for Online Conformance Checking
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Solution Overview
Problem
Existing methods for inspecting embossing on rod-shaped, multisegment articles are unreliable and offline, leading to high defective article rates and inefficient production.
Innovation Solution
Utilizing a 3D laser scanner for online and non-destructive inspection of embossing on a web of material, enabling accurate 3D reconstruction and virtual modeling to assess embossing quality, position, and type, with feedback control for corrective actions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If random visual inspection of articles is performed after tipping paper is enfolded, then operator safety is improved and manual inspection is simplified, but inspection reliability deteriorates and defective articles cannot be detected
Solution Approach 1:
The patent replaces manual visual inspection with an automated optical inspection system using cameras and light sources. The system captures images of the embossing on tipping paper during production and automatically analyzes them, eliminating the need for operators to manually examine each article while significantly improving detection reliability and consistency.
Solution Approach 2:
The inspection is performed on the tipping paper before it is enfolded around the rod-shaped articles. By inspecting the embossing in its accessible state on the flat paper, the system can detect defects early in the production process, allowing corrective actions to be taken before defective articles are formed.
2Measurement precision
If embossing inspection is performed after tipping paper is applied to articles, then article quality can be assessed, but all defective articles must be rejected increasing waste
Solution Approach 1:
The system performs inspection on the tipping paper web before it is cut and enfolded into articles. By detecting embossing defects early in the production process, the system enables selective rejection of only the defective portions of the paper web, rather than requiring rejection of entire articles that have already been manufactured.
Solution Approach 2:
The inspection process extracts and analyzes only the relevant embossing features from the tipping paper image data. This allows precise identification of defective areas, enabling the system to isolate and reject only the specific defective portions while preserving the rest of the production material.
3Reliability
If 3D laser scanner is used for online inspection, then inspection reliability and detection accuracy are improved, but device complexity increases
Solution Approach 1:
The system uses optical copying through cameras to create digital images of the embossing, which are then processed and analyzed. This approach achieves reliable detection through image analysis and computational methods rather than requiring complex mechanical measurement systems, thereby improving reliability while managing device complexity.
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
Ensures reliable, efficient, and precise conformance checking of embossing, significantly reducing defective articles and enabling continuous production quality control.
Implementation Method 1
light sources are used to illuminate the article and cameras are used to detect the light reflected by the article itself
Implementation Method 2
using a laser detector, in particular a 3D laser scanner, it is possible to perform a three-dimensional reconstruction of the embossing profile
Data Source
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AI summary
A method for determining the conformance of an embossing on a web of material, comprising a step of feeding the web of material along a feed path and a step of making a succession of embossings on the web of material. The method comprises a step of making a succession of rod-shaped, multisegment articles by means of at least one portion of the web of material so that each article is provided with at least one respective embossing. The method comprises a step of detecting, by means of an inspection module comprising a laser detector, at least one embossed portion of one or more of the embossings and, based on the detection, reconstructing a virtual 3D model of the embossed portion by means of a processing unit. The method comprises a step of processing the 3D model to generate at least one signal identifying one or more of the following conditions: embossing of a quality conformant or non-conformant with a reference quality for the current process; embossing correctly or incorrectly positioned; embossing of a type conformant or non-conformant with a type of embossing expected for the current process.