Optical Inspection Device for Sheet Product Quality Control
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Solution Overview
Problem
Current methods for controlling and sampling sheet products in packaging manufacturing are inefficient, requiring frequent production halts and manual intervention, leading to potential sample loss and increased operational costs due to the complexity of handling and quality control processes.
Innovation Solution
A system incorporating an optical monitoring device with a camera and control unit for automatic quality control, and an actuation element that cooperates with the pliers bar to eject samples automatically, allowing for regular quality checks without operator intervention and maintaining a straight trajectory for sample ejection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual sampling of poses is performed during production, then quality control can be carried out, but production must be strongly slowed down or temporarily stopped and operator intervention is required
Solution Approach 1:
The patent replaces manual mechanical sampling operations with an automated optical monitoring system. A camera captures images of the poses on the evacuation carpet, and image processing software automatically analyzes the quality parameters, eliminating the need for operator intervention and production stoppages while maintaining continuous quality control.
Solution Approach 2:
The system enables self-service quality control by automatically capturing, processing, and analyzing images of the poses without requiring external operator intervention. The optical monitoring device and image processing system work autonomously to detect quality defects and provide feedback, allowing the production process to continue uninterrupted.
2Reliability
If manual sampling is performed, then quality control is possible, but samples can be lost during handling or mixed with leaves
Solution Approach 1:
Instead of physically handling and removing actual pose samples, the system creates digital copies through optical imaging. The camera captures images of the poses on the evacuation carpet, and these digital representations are used for quality analysis, eliminating the risk of physical sample loss or contamination while maintaining accurate quality assessment.
Solution Approach 2:
The patent introduces an optical intermediary (camera imaging system) between the poses and the quality analysis process. Rather than directly handling the physical poses, the system uses light and digital image processing as intermediaries to extract quality information, preventing direct contact and potential sample loss or contamination.
3Device complexity
If ejection on the fly is used in waste evacuation station, then a bar of pliers is saved and machine complexity is reduced, but sample ejection requires additional mechanisms
Solution Approach 1:
The patent makes the existing ejector on the volley multi-functional by using it for both waste sheet ejection and pose sample ejection. The same mechanical structure serves dual purposes: ejecting waste sheets during normal operation and ejecting pose samples when quality control is required, eliminating the need for separate sample ejection mechanisms and maintaining machine simplicity.
Solution Approach 2:
The system merges the waste evacuation function and sample ejection function into a single integrated mechanism. The ejector on the volley is configured to handle both waste sheets and pose samples, combining what could have been separate operations into one unified system, thereby reducing overall device complexity while maintaining operational ease.
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
Enables efficient and regular quality control of sheet products during production, reducing operational disruptions and sample loss by automating the sampling process and maintaining a consistent, efficient ejection trajectory.
Implementation Method 1
The optical surveillance slide includes a camera or a camera and the control device has a control unit connected to the optical monitoring device, the control unit being configured to compare an image taken by the optical monitoring system with at least A reference image to determine the presence of a quality defect.
Data Source
Figure 1~2
Figure 3A~3C
Figure 4~5B
AI summary
The invention relates to a device (6) for inspecting exposure samples (P) for a machine (1) for processing sheet-shaped elements, the processing machine (1) comprising a plurality of workstations (300, 400, 500, 600) including at least one waste discharge station (600) comprising a discharge mat (93, 94), the inspection device (6) being characterized in that it comprises an optical monitoring device (7) configured to determine a quality defect of an exposure sample (P) lying on the discharge mat (93; 94). The present invention also relates to a waste discharge station (600), a machine (1) for processing sheet-shaped elements and a method for the quality control of exposure samples.