100% Inspection
This is an intelligent tool designed for the comprehensive inspection of printed and plain substrates like films, laminates, paper, fabrics, nonwovens, and more. It is particularly valuable for machines operating at speeds beyond the perceptual capabilities of the human eye.
The system is equipped with high-resolution cameras, monitors, and cutting-edge AI-based image processing software. It conducts real-time image comparisons with master templates, enabling the detection of imperfections that remain invisible to the naked eye. In addition, the system promptly triggers alerts to facilitate corrective actions during the ongoing production process. Additionally, it includes built-in features like alarms, warnings, and “digital roll-maps” to further enhance the quality control measures.
FAQs
What is a 100% surface inspection system?
A line scan camera-based 100% surface defect detection system is used during the process to continuously inspect the substrate for any deviations. It utilises high-resolution line scan cameras to capture data, and processing software to analyse the surface for defects.
How does a line scan camera-based system differ from other inspection methods?
Line scan camera systems capture images line by line, providing high-resolution scans of an entire surface, making them ideal for continuous and comprehensive inspection.
What types of defects can be detected by 100% surface inspection system?
The system can detect a wide range of defects, including holes, dents, dark spots, stains, gels, creases, fisheyes, wrinkles, splices, scratches, coating voids, insects, patches, and shade variations, besides others.
Can the system be integrated into existing production lines or machinery?
Yes, this system is designed for integration with existing production lines, allowing seamless inclusion in various industries.
Can the system handle different types of surfaces or materials like metals, plastics, gray fabric and non-woven?
Yes, these systems are versatile and can be configured to inspect various surfaces and materials commonly used across different industries.
How does the system adapt to different lighting conditions or environmental variations for accurate defect detection?
The systems use dark-field, bright-field and angular lighting besides incorporating adaptive features to handle varying ambient conditions.
Can the system be employed for historical defect analysis or trend identification for process improvement?
Yes, the system's stored data can be used to analyse historical defect patterns, identifying trends for continuous process improvement and maintenance.
What is a 100% print defect detection system?
A line scan camera-based 100% print defect detection system is used during the printing process to continuously inspect the print for any deviations when compared with print artwork. It utilises high-resolution line scan cameras to capture images, and image processing software to analyse the entire print repeat, ensuring 100% inspection of the production run.
How does a line scan camera-based defect detection system work?
The line scan camera has pixels arranged as a single row. This captures the image line by line as the substrate moves towards the rewinder. The image processing software recreates the print in real-time and analyses defects. Print defects like misprints, misregisters, color variations, streaks, hazing, and any other print related anomalies are detected. The system triggers an audio, visual alert for immediate corrective action as well as registers the defects as an electronic stamp. A roll-map is saved which has the x and y coordinates of each defect.
What are the most common types of defects this system can identify in printing?
Common defects that this system can detect include misprints, color variations, streaks, bleeding, missing or extra prints, ink splatters, registration errors, drags, holes and other imperfections that affect print quality.
Can this system be integrated into existing printing and inspection rewinder machinery?
Yes, the defect detection systems can be seamlessly integrated into any web based printing machine.
Is the system customisable for different printing applications and materials?
Yes, these systems are typically customisable and adaptable for different printing applications, substrates, and printing processes. They can be configured to suit specific requirements and adjusted for defect sizes, different materials, printing speeds, and defect identification parameters.
Can this system differentiate between critical defects and minor imperfections?
Yes, the system can be configured to distinguish between critical defects that impact the product's quality and minor imperfections that might not affect the overall usability. This customisation helps in setting different thresholds for defect identification.
Can this defect detection system provide Delta E (ΔE) values for color variation analysis?
The system gives a comparative Delta E value to evaluate colour variation. This value assists in examining the perceived difference between colours.
What is roll mapping in the context of rewinder control for printing or converting processes?
A roll-map is prepared for each printed roll. The roll-map captures information about a production run, such as roll length, location, and type of defects for quality control purposes. This roll-map can be loaded on an inspection rewinder machine. The QC checker can delete non-critical defects from the roll-map, retaining the critical ones. The final roll-map with critical defects is integrated with the inspection rewinder, stopping the machine at each defect. The operator can cut the defect portion from the roll, thereby, ensuring a defect free final product.
What level of support or service is provided after purchasing this system?
A.T.E. Service team provides technical assistance, software updates, calibration services, besides troubleshooting.
Are there options for remote troubleshooting or assistance for the defect detection system?
Yes, A.T.E. Service team provides remote troubleshooting, allowing technicians to diagnose issues and provide guidance or support without being physically present on-site.