Rewinding Machine Vision Control for Defect Localization
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing rewinding machines struggle with accurate defect localization and control of web material features during the rewinding process, particularly after the web material has been slit into longitudinal strips, leading to issues with reel quality and consistency.
Innovation Solution
A rewinding machine equipped with a web material evaluation system that includes video cameras and other sensors to capture images and measure features such as defects, width, and Poisson's ratio, allowing for real-time adjustment of winding parameters to ensure high-quality secondary reels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Difficulty of detecting and measuring
If vision systems and metal detectors are installed before the winder to control web material quality, then defect detection capability is improved, but defect localization accuracy deteriorates because the systems cannot account for dimensional changes during rewinding
Solution Approach 1:
The patent applies preliminary action by installing the evaluation system at the rewinder to detect defects before they are wound into the final reel configuration. This allows the system to identify and mark defects while the web material is still accessible and can be properly localized, accounting for dimensional changes that occur during the rewinding process. The evaluation system performs detection in advance of final reel formation, enabling accurate defect mapping to specific reels.
Solution Approach 2:
The patent implements feedback by using the evaluation system to continuously monitor web material quality during rewinding and providing real-time information about defect locations. This feedback loop allows the system to track dimensional changes and adjust defect localization accordingly, ensuring accurate mapping of defects to specific reels even as the web material undergoes tension and compression during the rewinding process.
2Productivity
If the web material is slit into longitudinal strips during rewinding, then productivity is improved by producing multiple secondary reels simultaneously, but manufacturing precision deteriorates due to difficulty in controlling strip width and edge position consistency
Solution Approach 1:
The patent replaces mechanical measurement and control methods with an optical evaluation system using video cameras and image processing. Instead of relying solely on mechanical cutting devices to maintain precise strip widths and edge positions, the system uses optical detection to continuously monitor strip dimensions and provide feedback for adjustments, enabling high-precision control while maintaining high productivity through multi-reel simultaneous production.
Solution Approach 2:
The patent uses video cameras to create optical copies (images) of the web material and strips during the rewinding process. These visual copies allow for precise measurement and analysis of strip width and edge positions without physically interfering with the cutting or winding process. The image data can be processed to detect deviations and provide feedback for maintaining manufacturing precision while producing multiple reels in parallel.
3Manufacturing precision
If real-time evaluation and adjustment of winding parameters is implemented, then manufacturing precision is improved, but device complexity increases due to additional sensors and control systems
Solution Approach 1:
The patent applies universality by designing an evaluation system that performs multiple functions simultaneously: defect detection, strip width measurement, edge position monitoring, and reel quality assessment. Rather than implementing separate specialized systems for each measurement, the evaluation system integrates these functions into a single multi-functional platform, reducing overall system complexity while maintaining high manufacturing precision through comprehensive real-time monitoring and 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
The system enables precise detection and correction of defects and dimensional changes, resulting in improved quality and consistency of secondary reels by adjusting tension and cutting parameters based on real-time data.
Implementation Method 1
The evaluation system is adapted to detect the position of longitudinal edges of the web material strips and, thus, determine their width and to detect defects
Data Source
AI summary
The machine (1; 100) comprises a winding station (3; 101), adapted to receive secondary winding cores (T) coaxial with, and adjacent to, one another. A cutting device (11; 104) is also provided, with a plurality of blades (13; 105), arranged upstream of the winding station (3; 101) with respect to the feeding direction of the web material (N) and adapted to subdivide the web material into plurality of strips (S1-S5) of web material; The machine has a web material evaluation system and a programmable unit (71) for processing data collected by the web material evaluation system.