Sanitary Article Machine Vision Inspection Synchronization
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Solution Overview
Problem
Existing machines for producing absorbent sanitary articles often reject both defective and non-defective products due to ambiguous signals from optical inspection systems, leading to significant waste of raw materials.
Innovation Solution
A machine equipped with a linear video camera and image processing unit that flags defects before cutting the continuous web into individual articles, using a programmable electronic controller to shift rejection information to a specific step in the shift register, ensuring only defective articles are rejected by synchronizing the inspection with the machine's production cycle.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If photocell inspection systems are used to detect defective articles, then defect detection is achieved, but ambiguous signals cause both defective and non-defective articles to be rejected
Solution Approach 1:
The patent replaces the mechanical photocell inspection system with a vision system comprising a linear video camera and image processing unit. This substitution eliminates the ambiguous random signals generated by photocells and provides precise defect detection through digital image analysis, thereby improving reliability without increasing false rejections and reducing raw material waste.
Solution Approach 2:
The patent introduces a microprocessor-based image processing unit as an intermediary between the video camera and the control system. This intermediary processes the video signals to accurately identify defective articles and generates precise rejection signals, eliminating the ambiguous signals that caused both defective and non-defective articles to be rejected together.
2Device complexity
If photocell signals are used without synchronization, then simple defect detection is achieved, but ambiguous concurrent signals create uncertainty windows causing excessive rejections
Solution Approach 1:
The patent implements a feedback mechanism where the microprocessor continuously monitors the position of the continuous web and synchronizes the rejection signal timing with the actual position of defective articles. This feedback loop eliminates ambiguity by ensuring rejection signals are sent at the correct moment, improving rejection accuracy while maintaining system reliability.
Solution Approach 2:
The patent uses periodic machine sync signals to synchronize the vision system and control operations. By aligning the inspection and rejection processes with the periodic production cycle, the system eliminates uncertainty windows and ensures that only truly defective articles are rejected, improving reliability without excessive complexity.
3Loss of time
If defective articles are rejected with a time delay, then defect identification is achieved, but the continuous web position changes causing incorrect article rejection
Solution Approach 1:
The patent performs preliminary actions by continuously tracking the position of the continuous web and pre-calculating the rejection timing based on web speed and defect location. This allows the system to send rejection signals at the precise moment the defective article reaches the rejection station, maintaining both rapid defect detection and high position accuracy.
Solution Approach 2:
The patent implements dynamic position tracking where the microprocessor continuously monitors and adjusts for changes in web position and speed. This dynamic adaptation ensures that rejection signals remain accurate even as production conditions change, maintaining manufacturing precision without sacrificing defect detection speed.
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
Minimizes the rejection of non-defective products by accurately identifying and isolating defective articles, reducing material waste and ensuring only defective items are discarded.
Implementation Method 1
a linear video camera and a connected image processing unit for detecting production defects in the made-up continuous web
Data Source
AI summary
A machine for making absorbent sanitary articles, where each article includes components progressively positioned relative to each other and assembled along a production line. The machine includes a programmable electronic controller device having a shift register, at least one optical inspection system connected to the programmable electronic controller device, and an operator interface connected to the electronic controller. The programmable electronic controller device generates a machine sync signal, a trigger signal for activating the optical inspection system in phase with the sync signal and a shift register shift command. The optical inspection system receives the trigger signal and has a defined maximum response time which produces at least one band of uncertainty. The operator sets with the operator interface the instant of activating the shift register shift command outside the band of uncertainty and between two consecutive sync signals defining a machine step.