Web Twist Detection and Auto-Correction in Narrow Web Processing
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Solution Overview
Problem
Current web processing operations face inefficiencies due to waste generation from defective products, machine downtime, and material twisting, which are not effectively identified until late in the manufacturing process, leading to reduced quality and production yield.
Innovation Solution
An apparatus and method utilizing machine vision systems and programmable controllers to inspect and correct web orientation and twist in real-time, preventing defective products from progressing through the manufacturing process and minimizing waste by applying discrete components only to conforming webs, and using guide plates and rotatable rings to self-correct twisted webs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If web processing operations continue without real-time inspection, then production speed is maintained, but waste increases due to defective products progressing through the manufacturing process
Solution Approach 1:
The machine vision system performs inspection early in the manufacturing process, before defective products progress through subsequent manufacturing steps. This preliminary detection allows for immediate correction or rejection of defective webs, preventing waste of additional materials and processing steps while maintaining continuous production flow.
Solution Approach 2:
The system provides real-time feedback through the programmable controller when defects are detected, enabling immediate corrective action. The feedback loop allows the system to adjust processing parameters or reject defective products on-the-fly, minimizing waste without requiring production slowdowns or stoppages.
2Manufacturing precision
If real-time inspection and correction systems are implemented, then product quality improves, but device complexity increases
Solution Approach 1:
The machine vision system serves multiple functions: it detects twists, determines orientation, triggers correction mechanisms, and provides feedback for quality control. By consolidating these functions into a single integrated system controlled by a programmable controller, the patent reduces overall system complexity while maintaining high product quality.
Solution Approach 2:
The system automatically detects and triggers correction actions without requiring manual intervention. The machine vision system and programmable controller work together to self-correct defective webs in real-time, reducing the need for complex manual monitoring and adjustment mechanisms.
3Productivity
If defective products are allowed to progress through the manufacturing process, then production flow is maintained, but quality deteriorates due to accumulation of defects
Solution Approach 1:
The machine vision system extracts or identifies defective products from the continuous production flow by detecting twists and orientation issues. Once detected, these defective webs are either corrected in-line or flagged for rejection, allowing them to be separated from the quality product stream while maintaining overall production continuity.
Solution Approach 2:
By detecting defects early in the process, the system takes preliminary action to correct or reject defective products before they accumulate additional defects or progress through subsequent manufacturing steps. This maintains production flow while ensuring quality standards are met.
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 in deposition of acquisition material (12), which on current machines frequently flips and is difficult to detect when it has flipped causing manufacturers to scrap thousands of products. Using the present invention, defects are able to be detected by discerning a difference in the appearance from side to side with a vision camera (18), and an acquisition inverter (10) can flip the material (12) to a correct orientation.