Apparatus and method for web twist defect correction
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Solution Overview
Problem
Current web processing operations face inefficiencies due to waste generation, machine downtime, and quality control issues, particularly in the production of disposable products like diapers, where defective products are identified late in the process, leading to unnecessary material recycling and reduced production yield.
Innovation Solution
Implementing a web processing system with integrated visual inspection and correction mechanisms that detect and correct twists in webs, and a programmable controller to manage the application of discrete components only if they meet inspection parameters, thereby minimizing waste and ensuring proper orientation and assembly.
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 late detection of defective products
Solution Approach 1:
The inspection system performs detection and correction actions before defective products are completed or shipped. The web inspection device identifies orientation issues early in the process, and the correction mechanism addresses them immediately, preventing waste generation rather than dealing with defects after production
Solution Approach 2:
The system implements continuous real-time feedback through the web inspection device that monitors web orientation and provides immediate information to the correction mechanism. This closed-loop feedback enables rapid response to defects without interrupting production flow, simultaneously reducing waste and maintaining productivity
2Loss of substance
If real-time web inspection and correction systems are implemented, then waste is reduced, but device complexity increases
Solution Approach 1:
The patent introduces a web inspection device and correction mechanism as intermediary components between the web processing stages. These intermediaries detect and correct orientation issues without requiring complete system redesign, integrating smoothly into existing web processing operations while achieving waste reduction
Solution Approach 2:
The correction mechanism automatically corrects web orientation issues upon detection without requiring manual intervention. The system serves itself by identifying and fixing defects in real-time, reducing waste while maintaining relatively simple operational procedures despite increased device complexity
3Manufacturing precision
If discrete components are applied only after inspection confirmation, then product quality improves, but production time increases
Solution Approach 1:
The inspection and component application processes operate continuously without interruption. The web moves continuously through the inspection device, and component application occurs in real-time as webs are confirmed to meet specifications, eliminating stopping and starting while maintaining quality control
Solution Approach 2:
The inspection occurs immediately before component application, confirming web suitability in advance. This preliminary verification ensures that only conforming webs receive components, preventing rework while maintaining continuous production flow and minimizing time loss
Data Source
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, 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, and an acquisition inverter can flip the material to a correct orientation.