Automatic Inspection Machine for Roll-Type Printing Products
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Solution Overview
Problem
Current roll-type printing product inspection is manual and inefficient, with high-speed products leading to missed defects and poor quality, and traditional machines are limited in functionality and automation, resulting in increased costs and labor.
Innovation Solution
An automatic quality inspection machine with a camera, light source, and multi-functional mechanisms for inspection, slitting, and material handling, including unrolling, rolling, and guiding rollers, connected to a main controller for high-precision defect detection and quick material replacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual quality inspection is used, then labor flexibility is maintained, but inspection precision and speed are insufficient leading to missed defects
Solution Approach 1:
The patent replaces manual visual inspection with an automatic inspection mechanism comprising a camera, light source, and control unit. The camera captures images of the roll-type printing product, the light source illuminates the product surface, and the control unit processes images to detect defects automatically, eliminating the need for manual inspection while achieving high precision and speed
Solution Approach 2:
The inspection system performs self-diagnosis and automatic defect detection through the camera and control unit, which continuously monitor the printing product and identify defects without human intervention, enabling the system to serve itself in the inspection process
2Productivity
If traditional single-function inspection machines are used, then device simplicity is maintained, but productivity and efficiency are limited
Solution Approach 1:
The patent integrates multiple functions into a single machine: the inspection mechanism detects defects, the slitting mechanism cuts defective portions, the unrolling device feeds the printing product, and the rolling device winds it up. This multi-functional integration enables one machine to perform inspection, defect removal, and material handling, significantly improving productivity while managing complexity through coordinated automation
Solution Approach 2:
The patent combines the inspection mechanism, slitting mechanism, unrolling device, and rolling device into an integrated system where all components work together on a single production line, merging previously separate operations into one coordinated machine that processes printing products continuously
3Loss of time
If manual defect removal is used, then operational flexibility is maintained, but time consumption and labor intensity increase
Solution Approach 1:
The control unit pre-identifies defective portions through image processing before the printing product reaches the slitting mechanism. The system calculates the exact position and dimensions of defects in advance, so when the product arrives at the slitting station, the cutting operation can be executed immediately without manual measurement or preparation, reducing time loss
Solution Approach 2:
The patent replaces manual defect removal with an automated slitting mechanism controlled by the control unit. The slitting mechanism receives cutting commands from the control system, automatically positions itself, and executes precise cuts to remove defective portions, eliminating manual labor while maintaining operational simplicity through centralized control
4Speed
If high-speed printing product movement is used, then production speed is improved, but inspection accuracy decreases due to motion blur
Solution Approach 1:
The inspection mechanism uses periodic flash illumination from the light source synchronized with the camera's image capture. The light source emits short, intense flashes at precise moments when the camera takes pictures, providing sufficient illumination to freeze motion and capture clear images of high-speed moving printing products without motion blur
Solution Approach 2:
The system performs preliminary positioning and synchronization of the camera and light source before actual inspection begins. The control unit pre-calculates the timing and position parameters based on product speed, ensuring that images are captured at optimal moments when the product is in the correct position and the lighting is perfectly synchronized, maintaining accuracy at high speeds
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 machine achieves high automation, precision, and efficiency in defect detection and material handling, reducing manual labor and increasing production efficiency while ensuring accurate inspection and quick material replacement.
Implementation Method 1
the inspection mechanism includes a camera for photographing a roll-type printing product, a light source for assisting the camera
Data Source
AI summary
The present invention has disclosed an automatic quality inspection machine and a control method thereof, which relates to the technical field of inspection devices. The machine comprises a frame, an unrolling device provided at the frame, an inspection mechanism, a button operating platform for removing a defective roll-type printing product, a slitting mechanism, a main controller, a display device, and a rolling device. The rolling device includes a first rolling mechanism and a second rolling mechanism, the first rolling mechanism includes a first rolling airshaft and a first outgoing feed roller corresponding to the first rolling airshaft; the second rolling mechanism includes a second rolling airshaft and a second outgoing feed roller corresponding to the second rolling airshaft. The automatic quality inspection machine has a number of advantages including multifunctional, highly automatic, and high inspection accuracy; the machine could quickly replace rolls and could effectively increase production efficiency.