Automated Web Threading for Elastic Laminate Defect Recovery
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Solution Overview
Problem
Current web processing operations face inefficiencies due to defects in elastic materials during laminate production, leading to system downtime and scrap products, and waste minimization is hindered by the inability to identify defective products early in the manufacturing process.
Innovation Solution
An automated method and apparatus for detecting defects in elastic materials and re-threading them through stretch rollers, combined with a system for inspecting continuous webs and patches to prevent defective products from being assembled, allowing for continuous processing and minimizing waste by identifying and isolating defective components early.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual inspection and re-threading of elastic materials is performed, then defective products can be identified and removed, but system downtime increases and productivity decreases
Solution Approach 1:
The patent replaces manual mechanical inspection and re-threading operations with an automated optical inspection system using cameras and image processing algorithms. The system automatically detects defects in elastic materials and controls re-threading operations, eliminating the need for manual intervention while maintaining high defect detection accuracy and preventing production interruptions.
Solution Approach 2:
The inspection system enables the manufacturing process to self-correct by automatically detecting defects and triggering re-threading operations without external human intervention. The system monitors the elastic material continuously and autonomously manages the removal and replacement of defective segments, allowing the production line to maintain continuous operation.
2Productivity
If continuous production is maintained without stopping for re-threading, then productivity is improved, but defective elastic materials may be processed leading to scrap products
Solution Approach 1:
The patent implements preliminary defect detection by positioning inspection cameras upstream in the production line, before the elastic material is fully processed. This allows defective materials to be identified early, and the system to automatically stop and initiate re-threading operations before defective segments are processed further, preventing scrap product generation while maintaining production continuity.
Solution Approach 2:
The system employs real-time feedback through continuous optical monitoring of the elastic material. Detected defect information is immediately fed back to the control system, which automatically adjusts the production process by triggering re-threading operations. This closed-loop feedback mechanism ensures that defective materials are identified and corrected in real-time, maintaining both productivity and product quality.
3Productivity
If automated defect detection and re-threading systems are implemented, then productivity and quality are improved, but device complexity increases
Solution Approach 1:
The patent integrates multiple functions into a unified automated system that combines optical inspection, defect analysis, and re-threading control. The inspection system serves multiple purposes: detecting defects, determining their severity, triggering appropriate responses, and monitoring re-threading operations. This multi-functional integration improves productivity while managing system complexity through consolidation rather than proliferation of separate components.
Data Source
AI summary
Apparatus and methods are provided to minimize waste and improve quality and production in web processing operations. A first non-elastomeric layer is bonded with an elastomeric layer, and to a second non-elastomeric layer. The apparatus and methods provide defect detection in the elastomeric layer and triggers an unthreading/rethreading sequence. Web defect detection may be provided by way of at least one visual inspection station. If defects are detected in the elastic layer, the resulting products may be culled.