Tube Cutting Device Using Pattern Correlation for Precision Detection
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Solution Overview
Problem
Existing methods for producing packaging tubes require optically prominent markings for accurate cutting, which disrupt the aesthetic quality and increase computational complexity, limiting production speed due to the need for high-resolution pattern recognition.
Innovation Solution
A method where a continuously fed tube with identical patterns is cut between individual patterns by activating cutting means based on optical scanning of a strip or line pattern, reducing the need for separate markings and minimizing hardware and computing effort by scanning only a significant section of the pattern, typically at least 20% of its length.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If optically prominent markings are used for accurate cutting detection, then cutting precision is improved, but the aesthetic quality of the tube is worsened and additional costs are incurred
Solution Approach 1:
The patent extracts the cutting detection function from separate prominent markings and integrates it into the existing individual pattern itself. The optical detector scans the pattern features that are already present for aesthetic purposes, and the control unit identifies cutting positions by analyzing correlations between successive patterns. This eliminates the need for additional UV markers or other optically prominent markings, maintaining aesthetic quality while achieving accurate cutting detection.
2Reliability
If full-area optical pattern recognition is used to detect cutting positions, then detection reliability is improved, but device complexity and computational effort increase significantly
Solution Approach 1:
The patent segments the optical scanning task by having the optical detector scan only specific features within the individual pattern rather than the entire pattern area. The control unit then uses correlation analysis between successive scanned features to reliably determine cutting positions. This segmented approach maintains detection reliability while significantly reducing sensor complexity and computational requirements compared to full-area pattern recognition.
3Manufacturing precision
If high-resolution full-area pattern scanning is performed, then cutting accuracy is improved, but production speed is reduced due to increased computation time
Solution Approach 1:
The patent applies partial action by scanning only the necessary features within the individual pattern rather than the entire pattern area. The optical detector captures key pattern features, and the control unit performs correlation analysis on this reduced data set to determine cutting positions with sufficient accuracy. This partial scanning approach maintains cutting accuracy while minimizing computation time, thereby preserving high production speed.
4Reliability
If separate marking systems are added to enable reliable cutting detection, then functional reliability is improved, but device complexity and manufacturing costs increase
Solution Approach 1:
The patent makes the existing individual pattern serve multiple functions: it maintains aesthetic appearance and simultaneously provides the optical features necessary for cutting detection. The optical detector and control unit are configured to scan and analyze the pattern features already present on the tube, eliminating the need for separate marking systems. This multi-functional use of the individual pattern improves operational reliability while avoiding additional device complexity and manufacturing costs.
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
Enables reliable detection and cutting of packaging tubes without optically disturbing markings, maintaining high production quality and speed by minimizing sensor complexity and computing effort, thus achieving efficient and accurate tube production.
Implementation Method 1
optical scanning of the tube, in the form of stripe or line patterns, along a feed direction
Data Source
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AI summary
The invention relates to a tube manufacturing device with means for feeding a tube tube (16) having a tube print, which comprises identical individual patterns (18) provided at regular intervals along a feeding direction (14), means (12) for cutting the tube tube (16) in a cutting direction between adjacent individual patterns (18) and control means (24) associated with the cutting means, which generate an activation signal (A) for the cutting means in response to an optical scanning of the tube tube (16), wherein the control means comprise an optical detector unit (20) which has an effective detector cross-section of no more than 10%, preferably no more than 2%, of a maximum width of the individual patterns (18) along the cutting direction and/or perpendicular to the feeding direction (14), and the control means comprise correlation means.which are designed to capture and store current first detector data of the detector unit (20) from a strip-shaped section of one of the individual patterns (18) and to correlate the first detector data with second detector data from a corresponding strip-shaped section of an upstream of the individual patterns (18) and/or with stored reference data of the individual patterns (18) and to generate the activation signal from this correlation.