Rubber Crumb Inspection System Contamination Detection
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Solution Overview
Problem
Current inspection methods for rubber crumb, which involve human or video inspection of rubber bales, are limited in detecting contamination within the bales as they only inspect less than 5% of the content and struggle to detect contaminants smaller than 0.5 mm, leading to a need for a more effective inspection system before the rubber crumb is pressed into a bale.
Innovation Solution
A rubber crumb inspection system comprising a controller, camera, and lighting positioned over a conveyor that illuminates and scans the rubber crumb to detect contamination by color contrast, with a rejection system to remove contaminants, allowing for inspection and removal of contaminants before baling, thereby increasing the purity of the product.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If human or video inspection of rubber bales is used, then inspection cost and complexity are reduced, but inspection coverage and detection precision deteriorate (less than 5% of content inspected, contaminants smaller than 0.5 mm difficult to detect)
Solution Approach 1:
The patent replaces manual human inspection and basic video inspection with an automated optical inspection system comprising a camera, lighting assembly, and controller. This substitution enables precise detection of contaminants as small as 0.08 inches while automating the inspection process, resolving the contradiction between detection precision and system complexity by using specialized optical equipment rather than human senses or simple video systems.
Solution Approach 2:
The patent introduces a rejection system as an intermediary component between detection and final product handling. When contaminants are detected by the camera system, the rejection system automatically removes them from the rubber crumb stream, enabling the inspection system to achieve high detection precision without requiring complete manual intervention, thus balancing detection capability with operational feasibility.
2Productivity
If inspection is performed after rubber crumb is pressed into a bale, then handling and inspection efficiency are improved, but inspection coverage and purity deteriorate (less than 5% of contents visible, contamination removal difficult)
Solution Approach 1:
The patent performs inspection and contaminant removal at the rubber crumb stage, before the material is compressed into dense bales. This preliminary action allows the optical system to inspect 100% of the rubber crumb surface area and remove contaminants while the material is still in a loose, accessible state, achieving both high productivity through automated processing and high purity through complete inspection coverage, unlike post-baling inspection where less than 5% of contents are visible.
3Quantity of substance
If automated inspection system with camera and lighting is implemented, then inspection coverage and detection capability are improved, but device complexity and initial cost increase
Solution Approach 1:
The patent designs the inspection system with multi-functional components that serve multiple purposes. The lighting assembly not only illuminates the rubber crumb for camera detection but also includes diffusers and reflectors to optimize light distribution. The controller integrates image processing, contaminant detection, and rejection system coordination into a single unit, enabling the system to achieve comprehensive inspection coverage without proportionally increasing overall system complexity through component consolidation and multi-functionality.
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 the inspection of a larger portion of the rubber crumb content, allowing for the detection and removal of contaminants as small as 0.08 inches, resulting in a higher purity product and improved utility of the rubber crumb.
Implementation Method 1
A rubber crumb inspection system is disclosed comprising a controller, camera and lighting positioned over a conveyor on which the rubber crumb travels such that the lighting illuminates the rubber crumb and the camera scans the rubber crumb to detect contamination by color contrast
Data Source
AI summary
An inspection system for inspecting rubber crumb includes a conveyor, lighting, a camera, and a controller. The conveyor is used to carry the rubber crumb. The lighting is positioned above the conveyor to illuminate the rubber crumb with at least 3,500 lumens. The camera is positioned adjacent to the lighting to take images of the illuminated rubber crumb in the lighted area. The controller receives the images from the camera and detects a contamination in the rubber crumb by determining whether there is a dark particle within the crumb. If a contamination is detected, it may be removed from the remaining rubber crumb.