"Web Defect Detector": for in-process material inspection
 Function:
The "Web Defect Detector" detects
defects in material as it is being processed.
The defects it detects are holes or flaws that
allows light to pass through. The "Web
Defect Detector" detects defects in such
materials as metal, paper, plastic, coated ,
etc.as they are being unrolled from their coiled
state or are being coiled. It detects defects
as small as 0.005" dia. at processing speeds
of up to 500 ft/min. It can detect larger defects
at higher processing speeds; such as 0.015"
dia. hole at speeds of 1500 ft/min. The size
defect it can detect is a function of the system's
speed of response and the rate of travel of
the web being coiled (see chart below). The
size defect the system can detect is also a
function of it's light intensity, striking the
photodetectors. The light intensity will decrease
as the distance between transmitter and receiver
increases. The optimum distance between the
transmitter and receiver is 3".
The system detects the location, across the
width of the material, inwhich the defect(s)
was detected and signals within 0.5" increments.The
"Web Defect Detector" has edge sensors
to track web wander, for accurately reporting
the defect locations. The edge sensors also
allow various width webs to be run without elaborate
new set-up. The linear measurement is derived
by either flagging the location by phyical means
or by time of signal, which the machine control
records in relationship to it's linear meter.
The material defect can now be removed from
the coil so that it does not cause failures
in the final product or failure of equipment
in the final or next process. |
| Benefits:
The system benefits the supplier by
allowing them to supply defect free material.
This superior product can provide a competitive
edge in the market place or can be used
to command a premium price. Plus, the
means inwhich the supplier can provide
defeat free product is demonstratable
and is not subject to human error; therefore
the quality is repeatable. The system
can also demonstrate "continuous
improvement" for Quality Management
Systems; such as ISO-9000. |
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| Cost advantages for the processor,
of the material, are numerous. Some advantages
are derived from savings within the production
processes, other advantages are derived from marketplace
advantages. All processors can save on; incoming
inspection, scraped product and final quality
control. Metal fabricators can save from cost
of repair to damaged equipment and dies caused
by defective material; including labor cost, down
time and lost production revenues. Others can
save from costs associated with failed products
in the supply chain,caused by defective material
such as; returns, lost customers, dissatisfied
consumers, lost advertising monies, etc. Where
health and safety issues are of concern the costs,
caused by defective material, can result in massive
costs for product recalls, law suits, etc. Industries
such as; food, pharmacutical, medical, etc can
allow contaminents ingress if defective material
is used in their packaging, resulting in health
problems. Other industries such as; beverage,
aerosole, pressurized containers, etc. can create
explosions if defective material is used in their
packaging, resulting in safety problems. Some
industries can incur costly in field repairs when
defective material is installed such as; landfill
liners, rubber roofs, laminates, ect. In some
industries, the defective material goes undetected
until additional labor and components are integrated,
such as; printed circuit boards with holes in
foils or laminates, electro-magnetic shields that
let emmissions to escape, wire insulation and
shielding that don't protect against electro-magnetic
disturbances, etc. In many cases the supplier
of the defective material can be held responsible,
or may share responsibilty, for damages caused
from the end product or process. |
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