Thermal Imaging for Extruded Strip Defect Detection
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Solution Overview
Problem
Existing defect detection systems for extruded strips, such as those used in tire manufacturing, are limited in their ability to detect broken or missing cords and uneven rubber distribution, often requiring costly and hazardous equipment, and may not function effectively with non-metallic or colored cords.
Innovation Solution
A defect detection system utilizing thermal imaging sensors to measure temperature differentials between rubber and cord materials as they exit the extruder, generating thermal maps and calculating metrics to identify defects like missing rubber or broken cords, which can be implemented with multiple sensors positioned strategically around the extruded strip.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If general-purpose two-dimensional cameras or three-dimensional cameras are used to detect surface contrast and structures, then surface defects can be detected, but broken cords and internal defects cannot be reliably detected
Solution Approach 1:
The patent replaces optical detection systems (cameras) with thermal imaging technology. Thermal imaging sensors detect temperature differences caused by defective cords, enabling detection of internal defects and broken cords that are invisible to optical cameras. This substitution allows comprehensive detection of all defect types including surface defects, internal defects, and broken cords.
Solution Approach 2:
The patent changes the detection parameter from optical properties (surface contrast, color) to thermal properties (temperature distribution). By measuring temperature differences between defective and non-defective cords, the system can identify broken cords and internal defects regardless of their visual appearance, thereby improving both measurement precision and adaptability.
2Measurement precision
If x-ray devices are used to detect internal structures and defects, then comprehensive defect detection is achieved, but implementation and operation costs increase significantly and health hazards arise
Solution Approach 1:
The patent replaces x-ray detection equipment with thermal imaging sensors. This substitution eliminates the health hazards and high costs associated with x-ray devices while maintaining the capability to detect internal defects. Thermal imaging provides a safe, non-ionizing alternative that achieves comparable or superior detection accuracy for cord defects.
Solution Approach 2:
The patent employs relatively inexpensive thermal imaging sensors instead of costly x-ray equipment. Thermal cameras are significantly cheaper to implement and operate, with no ongoing health safety costs, making this a cost-effective solution for internal defect detection in extruded products.
3Measurement precision
If sensors mounted to spools are used to detect cord breaks, then broken cords can be detected, but missing rubber material and uneven distribution cannot be detected
Solution Approach 1:
The patent implements a universal thermal imaging detection system that can identify all types of defects including broken cords, missing rubber material, and uneven distribution. By measuring temperature anomalies in the entire extruded product, a single thermal imaging system performs multiple detection functions that previously required separate specialized sensors.
Solution Approach 2:
The patent replaces spool-mounted mechanical sensors with thermal imaging technology. This substitution enables comprehensive defect detection including rubber material defects and distribution uniformity, not just cord breaks. The thermal imaging system captures temperature information across the entire product cross-section, providing versatile defect detection capability.
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 system effectively detects defects early in the manufacturing process, reducing waste and ensuring higher quality products by identifying temperature anomalies outside a tolerance range, regardless of cord material or color, and can be integrated with existing manufacturing processes with minimal modifications.
Implementation Method 1
A thermal imaging sensor, positioned to detect a plurality of surface temperatures on a surface of an extruded strip as the extruded strip exits the strip extruder
Data Source
AI summary
A defect detection system and method for detecting the presence of a defect in an extruded strip can include various elements. In examples, a thermal imagining sensor is used to detect a plurality of surface temperatures on a surface of the extruded strip. A processing unit is configured to generate a thermal map of an area of the surface of extruded strip. The processing unit is further configured to determine whether the plurality of surface temperatures are outside a tolerance range, indicating the presence of a defect in the extruded strip. Detecting a defect during the extrusion process can help achieve the goal of reducing manufacturing waste and increasing quality control.