3D Optical Sensor for Tobacco Rod End Face Profile Evaluation
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Solution Overview
Problem
The tobacco processing industry faces challenges in objectively evaluating the quality of rod-shaped product end faces due to subjective human assessment, which lacks reproducibility and comparability, and existing technologies are cumbersome and prone to errors in providing precise quantitative measurements.
Innovation Solution
A device equipped with a three-dimensional measurement system using an optical sensor and signal processing to determine the surface profile of the end face, allowing for quantitative evaluation of angles, fiber projections, and other criteria, enabling reproducible and detailed assessments without reference samples.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If subjective visual evaluation by human observers is used, then evaluation can be performed with simple equipment, but measurement precision and reproducibility deteriorate
Solution Approach 1:
The patent replaces the human visual evaluation system with an automated optical measurement system comprising a light source, camera, and image processing unit. This substitution eliminates subjective human judgment while maintaining equipment simplicity, achieving both objective measurement precision and operational ease through digital image analysis algorithms
Solution Approach 2:
The patent creates a digital copy of the end face surface through optical imaging and image processing. The captured image serves as a replicable digital representation that can be analyzed multiple times with consistent results, eliminating the variability of human observation while preserving the essential surface characteristics for evaluation
2Device complexity
If conventional optical devices with fixed focus lenses are used, then device complexity is reduced, but measurement precision and adaptability deteriorate
Solution Approach 1:
The patent replaces complex mechanical focusing mechanisms with a digital image processing approach. By capturing images at multiple focal planes and processing them computationally, the system achieves precise surface profile measurements without requiring mechanically adjustable focus lenses, thereby maintaining optical simplicity while enhancing measurement precision
Solution Approach 2:
The patent transitions from single-plane optical measurement to multi-plane volumetric measurement. By capturing images at different focal depths and processing them to reconstruct three-dimensional surface profiles, the system achieves precise depth information without adding complex mechanical focusing components to the optical path
3Measurement precision
If multiple light sources and complex aperture structures are used, then measurement completeness improves, but device complexity and ease of operation worsen
Solution Approach 1:
The patent employs a single light source that serves multiple functions: it illuminates the entire end face surface, creates appropriate contrast for fiber visualization, and enables depth perception through focus variation. This universal lighting approach achieves comprehensive surface measurement without requiring multiple specialized light sources or complex aperture arrangements
Solution Approach 2:
The patent uses digital image processing to create multiple virtual views and analyses from a single captured image. Through computational methods, the system extracts surface profiles, fiber orientations, and depth information without requiring physical multiple light sources or aperture structures, thereby simplifying the optical system while maintaining measurement completeness
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 provides precise, quantitative data for evaluating the quality of rod-shaped product end faces, enabling accurate comparison and optimization of production processes, with high spatial resolution and comprehensive assessment criteria such as ovality and roughness.
Implementation Method 1
The sensor is a two-dimensional optical distance or path measuring sensor, the radiation source being set up to generate a radiation fan in order to scan the end face of the rod-shaped product linearly
Data Source
AI summary
The device (10) has an optical displacement measurement sensor (13) e.g. three-dimensional camera system, for three-dimensional measurement of a surface profile of an entire front surface (51) of a rod-shaped product (50) e.g. cigarette. A signal processing and controlling device (24) e.g. computer, determines an angle of the front surface, and a positive/negative projection of fibers relative to the front surface based on measuring signals outputted by the sensor. The angle is determined as an inclination of a plane, which is adapted to a surface profile of the rod-shaped product. An independent claim is also included for a method for evaluating a front surface of a rod-shaped product of a tobacco processing industry.