Running Web Cuff Folding Correction With Vision-Guided Plow
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Solution Overview
Problem
Existing web processing systems fail to identify and correct cuff folding defects in real-time, leading to waste and inefficiencies due to the need for post-assembly recycling of defective products, which complicates the recycling process and reduces production quality and yield.
Innovation Solution
An automatic cuff folding defect correction system that includes a programmable logic controller (PLC) and machine vision systems to detect defects before assembly, and a retractable plow system to correct folding issues, ensuring that only defect-free materials are used in the assembly process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If real-time detection and correction systems are implemented, then production quality and yield improve, but device complexity increases
Solution Approach 1:
The machine vision system detects cuff folding defects before the assembly process, and the retractable plow corrects them in real-time. This preliminary detection and correction prevents defective materials from entering assembly, improving quality without requiring complex post-assembly inspection and rework systems
Solution Approach 2:
The patent replaces manual inspection and correction with an automated system combining machine vision (optical/electronic) for detection and a mechanically actuated retractable plow for correction. This substitution improves detection accuracy while keeping the correction mechanism relatively simple through automated control
2Manufacturing precision
If post-assembly recycling of defective products is required, then production quality control is maintained, but loss of time and productivity increase
Solution Approach 1:
By detecting and correcting cuff folding defects before assembly, the system prevents defective products from being manufactured in the first place. This eliminates the need for post-assembly recycling and rework, maintaining quality control while avoiding the time loss and productivity reduction associated with post-assembly defect handling
Solution Approach 2:
The system converts potential harmful defects (cuff folding issues) into correctable anomalies by detecting them early and using the retractable plow to adjust the fold during the running web process. This transforms what would be waste material requiring recycling into correctable defects that can be fixed in real-time, turning a productivity burden into a manageable process parameter
3Manufacturing precision
If post-assembly recycling processes are implemented, then defective products are handled, but device complexity and operational difficulty increase
Solution Approach 1:
The system performs detection and correction during the manufacturing process itself, before assembly is complete. This eliminates the need for separate post-assembly recycling operations, maintaining defect detection capability while greatly simplifying operations by handling everything in one continuous process flow
Solution Approach 2:
The retractable plow system automatically corrects cuff folding defects as they are detected, without requiring manual intervention or complex post-assembly recycling processes. The system serves itself by detecting and correcting its own defects in real-time, simplifying operation while maintaining high 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
Reduces waste by identifying and correcting cuff folding defects in real-time, improving production quality and yield by minimizing the need for post-assembly recycling and reducing machine downtime.
Implementation Method 1
machine vision systems to detect defects before assembly
Implementation Method 2
a retractable plow system to correct folding issues
Data Source
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AI summary
Apparatus and methods are provided to minimize waste and improve quality and production in web processing operations. The apparatus and methods provide defect detection both before and after application of component patches to a traveling web to create a product. Web defect detection may be provided by way of at least one visual inspection station located upstream from the patch applicator. Patch defect detection may be accomplished by way of a visual inspection station located proximate the patch applicator. If defects are detected in either the traveling web or the component patch prior to patch application, patch application may be prevented until both a satisfactory web and patch are provided. If defects are detected after patch application, the resulting product may be culled. Furthermore, the apparatus may be provided with diagnostic software to warn against extant or imminent machine complications.