Rewinder Log Winding Control Using Predictive Image Feedback
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Solution Overview
Problem
Conventional methods for assessing log formation during winding are manual and based on visual observations, leading to inefficiencies, reduced processing speeds, and increased operator intervention due to variability in winding processes, resulting in suboptimal machine productivity and quality issues.
Innovation Solution
The implementation of high-speed image capturing equipment and adaptive/predictive controls, combined with machine learning strategies, to accurately monitor log position, geometry, displacement, and vibration, reducing operator intervention and optimizing converting line performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual visual observation methods are used to monitor log formation, then operator intervention can detect quality issues, but processing speed must be reduced to safe speeds and operator time is required
Solution Approach 1:
The patent replaces manual visual observation with an automated image capture system using cameras and image processing algorithms. The system automatically captures images of the log during winding, detects vibration and quality issues through image analysis, and triggers alerts without requiring operator intervention. This substitution of mechanical/manual monitoring with automated optical detection resolves the contradiction by enabling continuous quality monitoring at high processing speeds without operator time requirements.
2Reliability
If conservative safe speeds are used to avoid vibration and quality issues, then log quality is maintained, but machine productivity decreases significantly
Solution Approach 1:
The patent implements a feedback control system where image capture equipment continuously monitors log formation and vibration in real-time. The system processes images to detect early signs of vibration and quality degradation, then provides feedback to control the winding process. This real-time feedback enables the system to operate at higher speeds while maintaining quality by dynamically adjusting parameters based on actual log conditions rather than relying on conservative fixed speed limits.
3Reliability
If pre-programmed adjustments based on assumed criteria are made, then some quality issues can be prevented, but adjustments may be inapplicable for particular conditions and operator time is still required
Solution Approach 1:
The patent enables the system to self-adjust based on real-time image analysis without requiring operator programming or intervention. The image processing algorithms automatically analyze log formation characteristics and trigger appropriate control adjustments based on detected conditions. This self-service capability allows the system to adapt to various product types and winding conditions dynamically, eliminating the need for pre-programmed adjustments for each specific condition while maintaining quality prevention.
Data Source
AI summary
A converting line includes a rewinding machine for winding web material into a log. For time points during a time period of the log wind cycle, predictive information representative of a log to be wound is generated and stored in a memory of a control of the rewinding machine. An image capture device is enabled to capture a plurality of images of the log being wound in the winding nest at the plurality of corresponding time points during the time period. Log image capture information is generated based upon the plurality of captured images and corresponding time points during the time period. The log image capture information is compared with the generated predictive log image information to determine a difference in log image. Revised predictive log image information is generated based at least in part upon a difference in the log image capture information relative to predictive log image information.