Optical Inspection Unit for Transparent Pack Defect Detection
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Solution Overview
Problem
Existing tissue paper production plants produce non-negligible quantities of defective products that are difficult to detect and remove, leading to production losses and quality issues, particularly with transparent packaging that is invisible to current detection methods.
Innovation Solution
A unit for controlling and managing products that includes image capturing means, such as smart cameras, to detect defects on the product surface, even on transparent packaging, by capturing images from multiple angles while products are in motion, and electronic processing to assess defects and trigger alerts or corrections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual inspection by machine operators is used to detect defective products, then detection capability is limited to visible defects, but transparent packaging makes defects invisible and difficult to detect
Solution Approach 1:
The patent applies lighting means that emit light at specific wavelengths to illuminate the transparent packaging, causing defects to become visible through changes in light reflection and refraction patterns. The lighting system creates optical conditions where defects on transparent surfaces manifest as detectable visual variations, effectively converting invisible defects into visible signals for detection.
Solution Approach 2:
The patent introduces lighting means as an intermediary element between the transparent packaging and the detection system. These lighting means modify the optical properties of the packaging surface, creating contrast and reflection patterns that make defects detectable by image capturing means, thus serving as a mediator that bridges the gap between transparent packaging and defect visibility.
2Productivity
If production speed is increased to meet demand, then productivity improves, but defect detection and removal becomes more difficult
Solution Approach 1:
The patent replaces manual mechanical inspection by operators with an automated optical detection system comprising image capturing means and lighting means. This automated system can operate at high speeds consistent with modern production lines, eliminating the trade-off between production speed and detection accuracy by using non-contact optical methods that can process products rapidly without compromising precision.
Solution Approach 2:
The patent implements defect detection during the production process itself, rather than as a subsequent manual inspection step. The detection system is positioned to capture images of products as they move along the production line, enabling real-time identification and immediate removal of defective products, thus maintaining high productivity while ensuring quality control.
3Measurement precision
If automated detection systems are implemented to detect defects, then detection precision improves, but system complexity and cost increase
Solution Approach 1:
The patent employs image capturing means that can serve multiple functions: capturing images of transparent packaging for defect detection, monitoring product positioning, and verifying packaging integrity. This multi-functional approach reduces the need for separate specialized devices, thereby lowering overall system complexity while maintaining high detection precision across different defect types.
Solution Approach 2:
The patent uses optical copying through image capturing means to create digital representations of the transparent packaging surfaces. These optical copies can be analyzed by processing systems to identify defects, replacing the need for complex physical inspection mechanisms. The copying approach simplifies the detection system by using non-contact optical methods rather than mechanical scanning or tactile sensors.
4Manufacturing precision
If comprehensive defect detection is implemented, then product quality improves, but production time increases due to manual removal
Solution Approach 1:
The patent implements a feedback system where the image capturing means continuously monitors products on the production line, and upon detecting defects, the system provides immediate feedback by triggering removal mechanisms. This closed-loop feedback approach enables real-time quality control without stopping production, as defective products are automatically identified and removed during continuous operation, maintaining both high quality and production efficiency.
Solution Approach 2:
The patent ensures continuous operation of the production line by implementing defect detection and removal during product movement rather than requiring batch inspection or production stoppages. The lighting means and image capturing means operate continuously alongside the production line, enabling uninterrupted detection and immediate removal of defective products, thus maintaining continuous productive action while ensuring quality control.
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 rapid detection and removal of defective products without disrupting normal plant operation, improving product quality and reducing production losses by identifying defects on transparent packaging effectively.
Implementation Method 1
The lighting means are adapted, or suitable for, producing different images of the respective product face, in particular which exhibit different states of reflection of the light that is incident upon the respective product face
Data Source
AI summary
A unit for the control or management of articles includes a plant including an operating line including an upstream section for making the articles, including a log saw for cutting rolls off elongate logs, a packaging section including a packing section where the articles or rolls are packed, and a bagging section where the packs are placed in bags and/or a palletizing section where the packs or bags are placed on pallets. A conveying section transports products between the upstream section and the packaging section and/or between one packaging section and another downstream. A process controller controls the functioning of the plant sections. The unit includes a device for detecting and/or lighting a face of the product or pack and which is adapted to produce different images of the face, to exhibit different states of reflection of the light that is incident upon the face.