Susceptor Cross-Section Inspection for Aerosol Article Defects
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Solution Overview
Problem
Existing methods for evaluating aerosol-generating articles with susceptor elements for manufacturing defects are inaccurate and time-consuming, particularly due to the high-speed nature of the manufacturing process, which does not allow for detailed evaluation of susceptor element positioning, shape, and cross-sectional dimensions.
Innovation Solution
A method involving digital image processing and edge detection is employed to record and analyze the intersection of the aerosol-generating article and susceptor element, using a camera system with illumination, to determine the cross-sectional shape, positioning, and length of the susceptor element, comparing these parameters to reference ranges for defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If visual inspection or traditional automated inspection methods are used, then manufacturing cost is reduced or equipment complexity is minimized, but manufacturing precision and defect detection capability deteriorate due to inability to detect subsurface or invisible defects
Solution Approach 1:
A susceptor element is introduced as an intermediary component within the aerosol-generating article. This susceptor contains magnetic particles that respond to magnetic fields, enabling indirect detection of defects through magnetic field interactions rather than direct visual or physical inspection of the defect itself
Solution Approach 2:
Traditional mechanical or visual inspection methods are replaced with a magnetic field-based detection system. The inspection process uses magnetic field interactions with the susceptor element to detect defects, substituting mechanical inspection with electromagnetic field-based measurement
2Reliability
If susceptor element with magnetic particles is introduced, then defect detection capability is improved through magnetic field interactions, but device complexity increases due to additional components and inspection equipment
Solution Approach 1:
The susceptor element serves multiple functions: it acts as a structural component of the aerosol-generating article (such as a heating element or component housing) and simultaneously functions as a defect detection target through its magnetic particle content. This multi-functionality reduces the need for separate dedicated detection components
Solution Approach 2:
The detection method utilizes changes in magnetic field parameters (strength, distribution, or response characteristics) when the aerosol-generating article is subjected to magnetic field exposure. Defects are detected by measuring these parameter changes rather than directly observing physical defects
3Manufacturing precision
If magnetic field exposure method is used for defect detection, then manufacturing precision is improved through detection of subsurface defects, but manufacturing time increases due to additional inspection steps
Solution Approach 1:
The magnetic field-based inspection process is designed to be continuous and integrated into the manufacturing flow. The susceptor element's magnetic response allows for rapid, non-contact detection that can be performed without interrupting or significantly slowing down the manufacturing process
Solution Approach 2:
The susceptor element with magnetic particles is pre-installed within the aerosol-generating article during manufacturing, before the final inspection stage. This preliminary preparation enables rapid defect detection during inspection without requiring additional preparation steps at the inspection stage
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
This method provides a quick and accurate evaluation of manufacturing defects by allowing for both approximated and refined assessments of susceptor element positioning, shape, and length, enabling continuous in-line detection and correction during the manufacturing process.
Implementation Method 1
evaluating an aerosol-generating article with a susceptor element for manufacturing defects
Data Source
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AI summary
The invention relates to a method for evaluating an aerosol-generating article with a susceptor element for manufacturing defects. The method comprises providing an aerosol-generating article with a substrate section, the substrate section comprising aerosol-forming substrate (24) and the susceptor element (26). The method furthermore comprises the method step of providing an intersection through the substrate section and the susceptor element. Another step includes evaluating the intersection for manufacturing defects by determining one or more of: positioning of the susceptor element in the substrate section, length of the cross section of the susceptor element, and shape of the cross section of the susceptor element. Therefor, in an embodiment a visual image of the intersection is divided into a plurality of segments (34), thereby creating an approximated circumference (22) of the cross-section with the susceptor element.