Operator Position Detection for Paper Converting Machine Setup
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Solution Overview
Problem
In paper converting machines, such as corrugating and box making machines, the preparatory work required to switch between different types of corrugated cardboard sheet or box production is time-consuming and inefficient, hindering production efficiency.
Innovation Solution
An analysis device and method that detects operator working positions, creates action diagrams, and generates work content item tables to identify improvement points in preparatory work processes, allowing for targeted efficiency enhancements by selecting and prioritizing improvement items based on prolonged working times, movement lengths, and inter-dependent tasks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual operation data collection methods are used to analyze preparatory work, then implementation complexity is low, but analysis accuracy and time efficiency are insufficient
Solution Approach 1:
The patent replaces manual observation and data collection methods with an automated image processing system. Cameras capture images of operators working in the paper converting machine, and image processing algorithms automatically analyze these images to extract working position data, action diagrams, and work content information. This substitution of mechanical/manual processes with automated optical and computational systems achieves higher measurement precision while managing system complexity through modular design.
Solution Approach 2:
The patent introduces an intermediary image processing system that acts as a mediator between the physical working environment and the analysis requirements. The image processing unit serves as this intermediary, capturing visual information from cameras and transforming it into structured data about operator actions, positions, and work content. This intermediary layer enables accurate analysis without requiring direct complex interaction with the operational system.
2Quantity of substance
If comprehensive monitoring of all operator actions is implemented, then work analysis completeness is high, but data processing burden and cost increase
Solution Approach 1:
The patent segments the monitoring and analysis process into distinct functional modules: camera units positioned at specific locations, image processing units that handle specific types of data extraction, and analysis units that process action diagrams and work content. This segmentation allows the system to manage large volumes of data by processing them in organized, manageable portions through specialized modules, improving overall processing efficiency while maintaining comprehensive monitoring.
Solution Approach 2:
The patent applies local quality by positioning cameras and image processing units at specific strategic locations within the paper converting machine to monitor particular work areas and operations. Rather than uniformly monitoring everything, the system concentrates monitoring resources on critical areas where preparatory work occurs, optimizing the balance between data completeness and processing efficiency by applying monitoring intensity locally where it matters most.
3Measurement precision
If detailed action diagrams and work content analysis are performed, then improvement identification accuracy is high, but analysis time and resource consumption increase
Solution Approach 1:
The patent implements preliminary action by continuously capturing images and pre-processing them into action diagrams and work content summaries in the background, before the actual analysis for improvement identification is needed. The image processing unit continuously extracts working position data and action information, preparing this data in advance so that when improvement analysis is required, the processed information is immediately available, reducing the time needed for final analysis while maintaining high accuracy.
Solution Approach 2:
The patent ensures continuity of useful action by maintaining continuous image capture and preliminary data processing operations that run concurrently with operator work activities. The camera units continuously monitor the work environment, and the image processing units continuously extract and update action diagrams and work content information. This continuous operation ensures that when improvement analysis is performed, the data is already processed and ready, eliminating idle processing time while maintaining high measurement precision throughout the work period.
Data Source
AI summary
An analysis device and an analysis method for a preparatory work time in a paper converting machine, includes an operator position detection device configured to detect a working position of an operator in the preparatory work time of a box making machine, an action diagram creation unit configured to create an action diagram of the operator based on the detection result of the operator position detection device, a work content item table creation unit configured to create a work content item table indicating a work content in the preparatory work time for each item based on operation processing data and operation data of the box making machine, and an operation process improvement item selection unit configured to select an improvement item of an operation process in the preparatory work time based on a creation result of the action diagram creation unit and the work content item table creation unit.