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Design and construction of an innovative testing device for very thin condoms using carbon fiber probes

Project Details

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In this project, a device for testing sanitary condoms was designed and built with the creative idea of using carbon fiber probes. In condom production lines, one of the problems is that not all condoms are perfect. Depending on the quality of the raw materials and the way they are molded, a significant number of condoms have holes.

In this device, after testing each condom, one of these 4 situations may occur:

1-Condoms without holes (Good)

2-Condoms that have a hole in the first area (the hole is in the upper third of the condom)

3-Condoms that have a hole in the second area (the hole is in the middle third of the condom)

4-Condoms that have a hole in the third area (the hole is in the bottom third of the condom)

Below you can see photos of this device in the research and development phase.

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Download Summary

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When the thickness of condoms is small, conventional condom testing devices have many errors in detecting holes on condoms, which leads to consumer dissatisfaction in addition to financial losses. Condoms are usually manufactured using the dipping method. If the position of the hole on the condom can be correctly identified, not only can healthy condoms without holes be distinguished from rejected condoms, but also the settings of the dipping system can be changed in a certain way to produce minimal waste, which is very important for the profitability of condom production factories.

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In this project, creative ideas were used to build a device that can detect holes in all types of very thin condoms (zero condoms) with an accuracy of 98.5%. Of course, it should be noted that the detection accuracy of the pilot version of this device is higher than 99%. In this project, the position of the hole on the condom can be identified in three areas. This tester is intelligent and can send all information and test results online to a database and receive and apply control commands from the factory DCS.

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As the main project progressed, some parts of the device were changed and new plans were implemented after the problems were solved.

This project has been divided into various sub-projects due to its large scope. I invite you to view the following projects related to this project on this website. The following videos show different parts of this test device and different phases of the research and development of this project.

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