Sensor-Based Pleat Counting for Air Filter Corrugated Sheets
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Solution Overview
Problem
Manual counting of pleats in air filter production is time-consuming and prone to errors, leading to potential faulty filters if the number of pleats is improperly counted.
Innovation Solution
A pleat counter system comprising a pleat detector mounted underneath a mounting board, with sensors to detect individual pleats and an interface for coupling with a data processing system, allowing for accurate and efficient counting of pleats in a corrugated sheet of filter material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual counting of pleats is used, then device complexity is reduced, but productivity decreases and measurement precision deteriorates
Solution Approach 1:
The patent replaces the manual mechanical counting process with an automated sensor-based detection system. Sensors mounted on a scanning device automatically detect and count pleats as the filter element moves through the scanning path, eliminating the need for manual visual inspection and counting by operators.
Solution Approach 2:
The scanning device with integrated sensors performs the counting function autonomously as it scans the filter element. The system self-records pleat counts and can automatically mark or signal when a predetermined number of pleats has been reached, without requiring continuous human intervention.
2Measurement precision
If manual counting of pleats is used, then device complexity is reduced, but measurement precision deteriorates
Solution Approach 1:
The patent replaces the manual mechanical counting process with an automated sensor-based detection system. Sensors mounted on a scanning device automatically detect and count pleats as the filter element moves through the scanning path, eliminating the need for manual visual inspection and counting by operators.
Solution Approach 2:
The sensor system creates an electronic record or signal pattern that corresponds to each pleat detected. This digital copy of the physical pleat structure allows for precise counting and verification, and can be stored or transmitted for quality control purposes.
3Loss of time
If manual counting of pleats is used, then ease of operation is maintained, but loss of time increases
Solution Approach 1:
The scanning device continuously scans the filter element as it moves through the production line, counting pleats without interruption. The sensors operate continuously along the scanning path, eliminating the stop-start nature of manual counting and maintaining continuous production flow.
Solution Approach 2:
The patent replaces the manual mechanical counting process with an automated sensor-based detection system. Sensors mounted on a scanning device automatically detect and count pleats as the filter element moves through the scanning path, eliminating the need for manual visual inspection and counting by operators.
Data Source
AI summary
A pleat counter and methods are provided to accurately count the number of pleats in a corrugated sheet of material to be used for the production of air filters. The pleat counter comprises a pleat detector mounted underneath a mounting board for counting the pleats. The mounting board is configured to position the pleat detector adjacent to the corrugated sheet of filter material. The pleat detector includes one or more sensors configured to detect the presence of individual pleats comprising the corrugated sheet. The pleat counter includes an interface configured to enable coupling the pleat counter with a data processing system. The data processing system may comprise any of a desktop, a tablet, a server, a mobile phone, a media player, a personal digital assistant (PDA), a personal communicator, a network router or hub, a wireless access point (AP) or repeater, a set-top box, or a combination thereof.