Optical Control Device for Cable Defect Detection
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Solution Overview
Problem
In the production of extruded or laminated bodies like cables and ropes, existing systems fail to timely identify defects on the outer surface or mark decay at high speeds, leading to inefficiencies and discarded products due to late detection of defects or mark errors, which requires interrupting the production line.
Innovation Solution
A compact optical control device with a movable optical assembly and motors allows for continuous monitoring of marks and defects on extruded bodies by acquiring and processing images along a curvilinear trajectory, enabling timely detection and prevention of errors without halting the production line.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If existing optical control systems are used to monitor marks and defects on extruded bodies, then quality control is performed, but the systems are too large to install without interrupting the production line and cannot detect defects timely at high speeds
Solution Approach 1:
The optical control system is divided into modular components: a support structure with multiple support arms, independently movable optical assemblies, and separate imaging units. This segmentation allows the system to be compact enough for inline installation without production interruptions while maintaining defect detection capabilities
Solution Approach 2:
The optical assemblies are positioned at multiple angular positions around the extruded body and can rotate to scan the surface from different perspectives. This multi-dimensional approach enables comprehensive defect detection on high-speed moving products without requiring the entire production line to stop
2Productivity
If the production line operates at high speed, then productivity is improved, but defects and mark decay are not detected timely leading to product waste
Solution Approach 1:
The optical assemblies continuously scan and capture images of the extruded body surface during production. By performing preliminary detection at the point of manufacture, the system identifies defects and mark issues before they result in wasted product, allowing real-time quality assurance without reducing production speed
Solution Approach 2:
The system processes captured images in real-time and provides feedback on mark quality and surface defects. This feedback mechanism enables timely detection and potential adjustment of marking processes while maintaining high production speeds, preventing defective products from being produced further
3Ease of operation
If a compact optical control device is installed, then ease of installation is improved and production line interruption is avoided, but device complexity must be managed
Solution Approach 1:
The optical assemblies are designed to perform multiple functions: capturing images of marks, detecting surface defects, and monitoring product quality. This multi-functionality reduces the need for multiple separate devices, simplifying installation while maintaining comprehensive monitoring capabilities despite the inherent complexity of the optical components
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 solution ensures continuous quality monitoring and timely detection of defects or mark decay, preventing production interruptions and reducing waste by allowing for real-time identification and adjustment of marking processes.
Implementation Method 1
an optical assembly (3) adapted to acquire or reconstruct an image of a portion (21) of the cable or extruded body at a mark provided on the cable (2)
Data Source
AI summary
A device for optically controlling a defect or a mark on a cable or an extruded body has a supporting guide arranged close to the cable or the extruded body in a manner spaced apart therefrom. The device has an optical assembly for acquiring or reconstructing an image of a portion of the cable or extruded body at the defect or mark that is engaged to the supporting guide and movable along a curvilinear trajectory. A first motor moves the optical assembly along the curvilinear trajectory. An electronic control unit starts acquisition of the image of the portion of the cable or extruded body by the optical assembly and processes the image to extract information relative to the defect or mark. A method for optically controlling a mark or defect applied to the cable or extruded body involves comparing reference information stored on the electronic unit with current information about an extracted mark or defect from the acquired image.