Apparatus and method for detecting longitudinally oriented flaws in a moving web
First Claim
1. A method for detecting longitudinally oriented flaws in a moving web having a width, comprising:
- transporting the web in a first direction at a pre-determined rate of motion;
positioning an array of cameras across the web width, transverse to the first direction of the moving web;
imaging adjacent columns of a surface of the web on a first side thereof, at a continuously adjustable non-synchronized rate relative to the rate of motion of the web;
collecting image data corresponding to said columns imaged by said cameras;
processing the image data in real-time by averaging columns of image data, to produce a width-wise profile across the full web width;
transmitting said averaged image data to a processing unit; and
detecting longitudinally oriented flaws from said averaged image data.
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Abstract
An optical inspection apparatus detects faults in a material coated on a moving web. Multiple cameras are positioned in an array across the width of the web transverse to the direction of the moving web. Each camera comprises a electronic camera and digital signal processor. An illumination source is preferably positioned to illuminate one side of the web. The camera array is positioned on the opposite side of the web aligned with the illumination source. The cameras in the array image the moving web along colas and collect image data from the web. The image is digitized and processed in real-time by averaging each column of image data to produce a profile of light intensity transmitted across the web width from which faults occurring in the longitudinal direction are detected in a host computer.
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Citations
17 Claims
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1. A method for detecting longitudinally oriented flaws in a moving web having a width, comprising:
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transporting the web in a first direction at a pre-determined rate of motion; positioning an array of cameras across the web width, transverse to the first direction of the moving web; imaging adjacent columns of a surface of the web on a first side thereof, at a continuously adjustable non-synchronized rate relative to the rate of motion of the web; collecting image data corresponding to said columns imaged by said cameras; processing the image data in real-time by averaging columns of image data, to produce a width-wise profile across the full web width; transmitting said averaged image data to a processing unit; and detecting longitudinally oriented flaws from said averaged image data. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15)
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16. A method for detecting longitudinally oriented flaws in a moving web having a width, comprising:
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transporting the web in a first direction at a pre-determined rate of motion; positioning an array of cameras across the web width, transverse to the direction of the moving web; determining a light operation level for said cameras; determining an imaging rate in response to said light operation level; imaging adjacent columns of a surface of the web on a first side thereof, at a continuously adjustable non-synchronized rate relative to the rate of motion of the web; collecting image data corresponding to said columns imaged by said cameras; processing the image data in real-time by averaging columns of image data, to produce a width-wise profile across the full web width; transmitting said averaged image data to a processing unit; and detecting flaws from said averaged image data.
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17. An optical inspection apparatus for detecting longitudinally oriented flaws in a web moving in a first direction at a pre-determined rate of motion, comprising:
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an array of cameras spaced from the web and directed toward a first surface of the web, said array extending across the width of the web such that a complete field of view of the web is achieved across adjacent columns of said web, each camera including an digital signal processor controller for collecting and continuously averaging image data from the surface of the web in real-time by averaging data columns from the image data to produce a width-wise profile of light intensity transmitted across the web width; and a continuously adjustable controller controlling the rate at which the image data is collected such that the rate is non-synchronous relative to the pre-determined rate of motion of the web.
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Specification