Optical Inspection of Paper Box Blanks Using Variable Wavelength Illumination
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Solution Overview
Problem
Current technologies for verifying the quality of paper box blanks during manufacturing are inadequate, as they often fail to accurately assess the pattern of glue application, print quality, and fold accuracy, leading to errors and increased costs due to inefficient quality control in the packaging industry.
Innovation Solution
A method and system utilizing optical sensors and a variable wavelength illumination source to inspect box blanks, comparing received images to stored product profiles to determine conformance to target parameters, including print registration and fold quality, allowing for real-time identification and rejection of defective boxes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional quality verification methods are used, then production can continue without interruption, but measurement precision and manufacturing precision are insufficient leading to undetected errors
Solution Approach 1:
The patent replaces manual visual inspection and simple mechanical sensors with an automated optical imaging system that captures images of box blanks and uses image processing to verify glue patterns, print registration, and fold accuracy. This substitution of mechanical/optical systems for manual inspection dramatically improves measurement precision while the automation reduces operational complexity.
Solution Approach 2:
The system creates digital copies (images) of the box blanks and their features (glue lines, prints, folds) to analyze quality attributes. By working with image copies rather than direct physical measurement, the system achieves high precision verification without complex physical measurement devices.
2Manufacturing precision
If advanced quality inspection systems are implemented, then manufacturing precision can be improved, but productivity decreases due to production interruption
Solution Approach 1:
The inspection system is designed to operate continuously alongside the box blank production line without stopping or slowing down manufacturing. Images are captured and analyzed in real-time as box blanks move through the production process, maintaining continuous production flow while achieving high manufacturing precision through automated verification.
Solution Approach 2:
By replacing manual inspection processes with automated optical imaging and image analysis, the system eliminates the need to stop production for quality checks. The automated system processes images rapidly, enabling continuous production while maintaining high precision quality control.
3Adaptability or versatility
If multiple finishing operations are performed on box blanks, then product differentiation is improved, but the opportunity for errors increases
Solution Approach 1:
The inspection system provides immediate feedback on the quality of each box blank after finishing operations. By detecting errors in glue application, print registration, and fold accuracy right after they occur, the system enables real-time corrective actions, preventing defective boxes from advancing further in the production process and reducing overall error rates.
Solution Approach 2:
The automated optical inspection system objectively detects quality attributes with high precision, eliminating human error and subjectivity. This mechanical/optical verification system reliably identifies errors across multiple finishing operations, ensuring consistent quality standards are met regardless of the complexity or number of operations performed.
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
This approach enables robust, cost-effective, and transparent quality control, ensuring the delivery of high-quality paper boxes by accurately assessing glue patterns, print registration, and fold accuracy without interrupting production, thereby reducing errors and production downtime.
Implementation Method 1
An illumination source illuminates at least that portion of the box blank including the feature
Implementation Method 2
An optical sensor receives an image of the illuminated portion of the box blank
Data Source
AI summary
A method for inspecting a feature applied to a box blank during manufacture of a paper box, comprising the steps of illuminating at least that portion of box blank including the feature with an illumination source, receiving an image of the illuminated portion of the box blank from at least one optical sensor, varying a characteristic of the illumination source for optically distinguishing between the feature a surface of said portion of the box blank to which the feature is applied, comparing the received image to a stored product profile containing an optimal image of the feature to determine if features in the received image are similar to the features in the stored product profile, and using the comparison to indicate when the box blank does not conform to the product profile.