Automated Pleat Counting System for Flexible Fabrics
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Solution Overview
Problem
The existing systems for counting pleats in fabrics for window coverings are manual and time-consuming, making it difficult to customize individual fabric packages efficiently.
Innovation Solution
A system comprising a carrier with a measuring area, a light source, a camera, and a processor that aligns the fabric, makes image recordings, analyzes contrast, and counts the number of corrugations, providing real-time feedback and dynamic customization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual counting of pleats is performed, then accuracy can be maintained, but time consumption increases significantly
Solution Approach 1:
The patent replaces the manual mechanical counting process with an automated optical measurement system. A camera captures images of the fabric pleats, and image processing algorithms automatically count the pleats by detecting edges and contours. This substitution of mechanical manual counting with automated optical-mechanical systems resolves the contradiction by providing both high accuracy through algorithmic edge detection and high speed through automated image processing.
Solution Approach 2:
The system enables self-service automated counting without requiring operator intervention. The camera automatically captures images, the processor analyzes the images to detect pleat edges and contours, and the system outputs the count automatically. This self-service automation eliminates time-consuming manual counting while maintaining accuracy through consistent algorithmic measurement.
2Productivity
If automated counting systems are used, then productivity increases, but measurement precision may deteriorate
Solution Approach 1:
The patent employs sophisticated image processing algorithms that analyze edge detection, contour following, and pattern recognition to accurately identify and count pleats. These computational methods provide consistent and precise measurements while operating at high speed, thereby achieving both high productivity and high measurement precision simultaneously.
Solution Approach 2:
The system incorporates feedback mechanisms where the camera captures real-time images of the fabric, the processor analyzes the images to detect pleat features, and the results are fed back for verification. This feedback loop ensures measurement precision is maintained while enabling high-speed automated counting, resolving the contradiction between productivity and precision.
3Adaptability or versatility
If complex fabric patterns and translucent materials are measured, then versatility improves, but difficulty of detecting and measuring increases
Solution Approach 1:
The patent applies local quality analysis by examining specific regions of the fabric image individually. The image processing algorithm analyzes local edge patterns, contour characteristics, and texture features in different areas of the fabric. This localized analysis enables the system to adapt to various fabric types, patterns, and translucency levels, improving versatility while managing detection complexity through region-by-region processing.
Solution Approach 2:
The system dynamically adjusts measurement parameters such as image processing thresholds, contrast enhancement levels, and edge detection sensitivity based on the specific fabric characteristics being measured. By changing these parameters adaptively, the system can accurately measure diverse materials including translucent fabrics and those with complex patterns, thereby improving versatility without being overwhelmed by detection complexity.
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
The system enables fast and reliable counting of pleats, allowing for accurate customization of fabric packages, even with translucent materials and complex patterns, thereby improving production efficiency.
Implementation Method 1
a light source (13) for illuminating the measuring area (12) on the carrier (10)
Implementation Method 2
The counting takes place by means of a photocell that captures light reflections from the pleats and a detector that converts the light reflections into pulses
Data Source
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AI summary
The invention relates to a system (1) for counting corrugations in a flexible material (100). The system is provided with a carrier (10) with a measuring area (12) and with aligning means (14) for aligning the flexible material in the measuring area, a light source for illuminating the measuring area, a camera for making one or more image recordings of the measuring area and a processor (23), which is arranged for counting the number of corrugations in one or more of the image recordings. The invention also relates to a method for counting a desired number of corrugations in a flexible material, for example pleats in fabric for a window covering, such as a pleated curtain. The invention furthermore relates to a computer program comprising instructions for carrying out the steps of the method.