Tyre Semi-Finished Product Residue Detection via Brightness Thresholding
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Solution Overview
Problem
The issue in the tyre building process is the presence of residues from service fabric and adhesive tape on semi-finished products, which can prevent correct adhesion between tyre components, leading to structural and performance issues, and are difficult to detect, especially when the tape is transparent or small.
Innovation Solution
A method and apparatus using an artificial vision/detection system to set brightness thresholds for detecting residues by comparing image brightness values, generating notification signals to deactivate unwinding or movement when residues are detected, and optimizing detection with background walls to enhance contrast and accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional detection methods are used, then the detection system is simple, but residues of service fabric and adhesive tape cannot be reliably detected
Solution Approach 1:
The patent replaces traditional mechanical or manual inspection methods with an artificial vision system using cameras and image processing algorithms. This optical/electronic system automatically detects residues by analyzing brightness values and patterns in images, achieving reliable detection of transparent or small residues without manual intervention.
Solution Approach 2:
The patent changes the detection parameter from visual inspection to quantitative brightness value analysis. By setting brightness thresholds and analyzing pixel intensity values in digital images, the system can objectively identify residues based on their optical properties, enabling automated and consistent detection.
2Reliability
If manual inspection is used, then the detection system is simple, but detection reliability is low due to difficulty in detecting transparent or small residues
Solution Approach 1:
The patent replaces manual inspection with an automated artificial vision system that uses cameras, lighting, and image processing. This system automatically captures images, analyzes brightness values, identifies residues based on threshold comparisons, and generates detection results without human intervention, ensuring consistent and reliable detection.
Solution Approach 2:
The detection system performs self-inspection by automatically analyzing images of the semi-finished products. The system independently sets brightness thresholds, processes images, identifies residues, and generates detection signals without requiring external manual intervention, achieving reliable automated detection.
3Reliability
If residues are not detected, then manufacturing efficiency is high, but structural and performance issues occur in tyres
Solution Approach 1:
The patent implements detection before the semi-finished products are used in tyre building. By inspecting products in advance and identifying residues early in the manufacturing process, the system prevents defective products from proceeding to subsequent stages, ensuring structural integrity while maintaining efficiency through early intervention.
Solution Approach 2:
The detection system provides feedback by generating detection signals when residues are identified. This feedback mechanism allows the manufacturing process to respond by diverting or reprocessing affected semi-finished products, ensuring that only quality-assured products proceed to tyre building, thereby maintaining both reliability and productivity.
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 approach allows for accurate and reliable detection of service fabric and adhesive tape residues, reducing the number of discarded tyres and improving manufacturing efficiency by ensuring cleaner semi-finished products before building.
Implementation Method 1
at least a first detection device (110) to detect at least a first image (A) representative of the semi-finished product (10)
Data Source
Figure 1
Figure 2a~2b
Figure 2c~2d
AI summary
A method and apparatus to control manufacturing and feeding of semi-finished products in a tyre building process, said method comprising: detecting at least a first image (A) representative of a semi-finished product (10) wherein said first image (A) is formed by a plurality of first portions (Al, A2), each one associated to a respective brightness value; defining a first threshold (THl) for said brightness values so that by arranging a first linear scale of the brightness values, defined between a first value (VI) corresponding to a null brightness value and a second value (V2) corresponding to a maximum brightness value, wherein the absolute value of the difference between said first value (VI) and said second value (V2) defines an amplitude of said first scale, said first threshold (THl) is such that the absolute value of the difference between said first threshold (THl) and said first value (VI) is comprised between about 5% and about 20% of the amplitude of said first scale; performing a first comparison between the brightness value of said first portions (Al, A2) and said first threshold (THl); as a function of said first comparison, determining a first operating parameter (PI) representative of an overall area occupied in said first image (A) by the first portions (Al) associated to a brightness value higher or lower than said first threshold (THl); performing a second comparison between said first operating parameter (PI) and a second threshold (TH2); if said first operating parameter (PI) is lower or higher than said second threshold (TH2), causing the generation of a first notification signal (NS1). An apparatus to control manufacturing and feeding of semi-finished products in a tyre building process is also described.