Flexible Ribbon Alignment Control With Real-Time Visual Feedback
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing manufacturing processes for flexible ribbon products are inefficient due to the need for manual quality monitoring and subsequent manual adjustments of production equipment, leading to reduced production efficiency when unqualified products are detected.
Innovation Solution
A manufacturing system that includes production equipment, a control device, and a signal adjustment device with a visual device and computer to capture real-time images, calculate and adjust the offset distance between the insulation film and forming area, and automatically adjust control signals in real-time to synchronize wire and tape conveying speeds, ensuring optimal production parameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual quality monitoring is used to detect unqualified flexible ribbon products, then quality control is achieved, but production efficiency is reduced due to system shutdown and manual parameter adjustment
Solution Approach 1:
The system implements self-service quality control through automatic visual inspection and real-time parameter adjustment. The visual device automatically detects offset distances, and the control device automatically adjusts conveying speeds without manual intervention, enabling the system to self-correct quality issues while maintaining continuous production
Solution Approach 2:
The system establishes a closed-loop feedback mechanism where the visual device continuously monitors the offset distance between insulation films and forming areas, and the control device receives this feedback to automatically adjust conveying speeds. This real-time feedback loop ensures quality control while preventing production interruptions
2Manufacturing precision
If manual adjustment of working parameters is performed after quality issues are detected, then production parameters can be corrected, but production efficiency is greatly reduced due to system shutdown
Solution Approach 1:
The system performs preliminary action by proactively and continuously monitoring the offset distance between insulation films and forming areas before quality defects occur. The real-time detection enables preventive adjustment of conveying speeds, avoiding the need for shutdowns and manual corrections
Solution Approach 2:
The system replaces manual mechanical adjustment with automated electronic control. The control device automatically adjusts conveying speeds based on visual inspection data, eliminating the need for manual parameter modification and system shutdowns while maintaining precise manufacturing accuracy
Data Source
AI summary
A manufacturing system includes equipment adapted to produce a flexible ribbon product, a control device adapted to control working parameters of the production equipment, and a signal adjustment device adapted to adjust control signals of the control device online and in real time to adjust the working parameters. The signal adjustment device includes a visual device for capturing online and real-time images of the flexible ribbon product produced by the production equipment, and a computer. The computer includes a calculation module adapted to calculate an offset distance between an insulation film on the produced flexible ribbon product and a forming area online and in real-time based on the captured images, and an adjustment module adapted to adjust the control signals of the control device online and in real-time based on the calculated offset distance until the offset distance is equal to zero.