Systems and methods for monitoring manufacturing processes
AssigneeHutchinson Technology Incorporated
InventorsJeffrey L. Roepke, John M. Kaiser, Joel D. Millett
Life of this patent
Estimating the term…
Abstract
A system for monitoring a process step during manufacturing of an assembly sheet includes a detection camera configured to capture a first image of the assembly sheet, the first image including a locating feature of the assembly sheet, a vacuum hold-down device for selectively inhibiting advancement of the assembly sheet along a process step line for a predetermined measurement time, and a measurement camera configured to capture a second image of the assembly sheet responsive to the vacuum hold-down device inhibiting advancement of the assembly sheet, the second image including one or more features of a coupon of the assembly sheet.
Claims46
A method for monitoring a process step during manufacturing of a plurality of assembly sheets, the method comprising:
- with the plurality of assembly sheets advancing between a first roll and a second roll, receiving, from a first camera, a first set of image data reproducible as a first image of a first portion of a first assembly sheet of the plurality of assembly sheets;
- analyzing, using one or more processors, the first set of image data to identify a locating feature of the first assembly sheet;
- determining, using at least one of the one or more processors and the first set of image data, a position of the locating feature relative to the first camera;
- based on the determined position of the locating feature and a predefined distance between the first camera and the second camera, determining a first assembly sheet stop time;
- inhibiting further advancement of the first assembly sheet;
- receiving, from the second camera, a second set of image data reproducible as a second image of a second portion of the first assembly sheet;
- analyzing, using at least one of the one or more processors, the second set of image data to identify a coupon of the first assembly sheet;
- detecting, using at least one of the one or more processors, one or more features of the identified coupon;
- measuring, using at least one of the one or more processors, one or more dimensions of the one or more detected features of the identified coupon;
- and
- permitting advancement of the first assembly sheet.
A system for monitoring a process step during manufacturing of an assembly sheet, the system comprising:
- a detection camera configured to capture a first image of the assembly sheet, the first image including a locating feature of the assembly sheet;
- a vacuum hold-down device for selectively inhibiting advancement of the assembly sheet along a process step line;
- and
- a measurement camera configured to capture a second image of the assembly sheet responsive to the vacuum hold-down device inhibiting advancement of the assembly sheet, the second image including one or more features of a coupon of the assembly sheet.
A system for monitoring a process step during manufacturing of a plurality of assembly sheets, the system comprising:
- at least one detection camera;
- at least one measurement camera positioned downstream relative to the detection camera in the process line;
- a vacuum hold-down device;
- one or more processors;
- and
- a memory device storing instructions that, when executed by at least one of the one or more processors cause the system to,
- receive, from the at least one detection camera, a first set of image data reproducible as a first image of a first portion of a first assembly sheet of the plurality of assembly sheets;
- analyze, the first set of image data to identify a locating feature of the first assembly sheet;
- determine, a position of the locating feature relative to the at least one detection camera;
- based on the determined position of the locating feature and a predetermined distance between the locating feature and a coupon of the first assembly sheet, determine a first assembly sheet stop time;
- activate the vacuum hold-down device to inhibit further advancement of the first assembly sheet;
- receive, from the measurement camera, a second set of image data reproducible as a second image of a second portion of the first assembly sheet;
- analyze the second set of image data to identify one or more features of the coupon of the first assembly sheet;
- measure one or more dimensions of the one or more identified features of the coupon;
- and
- deactivate the vacuum hold-down device to release the first assembly sheet and permit advancement of the first assembly sheet.
A method for monitoring a process step during manufacturing of a plurality of assembly sheets, the method comprising:
- receiving, from a first camera, a first set of image data reproducible as a first image of a first portion of a first assembly sheet of the plurality of assembly sheets;
- determining, using the first set of image data, a position of a locating feature of the first assembly relative to the first camera;
- inhibiting further advancement of the first assembly sheet such that one or more coupon features of the first assembly sheet are positioned with a field of view of a second camera for a predetermined measurement period;
- receiving, from the second camera, a second set of image data reproducible as a second image of a second portion of the first assembly sheet;
- analyzing the second set of image data to identify the one or more coupon features of the first assembly sheet;
- measuring one or more dimensions of the one or more coupon features of the first assembly sheet;
- and
- responsive to determining that the predetermined measurement period has elapsed, permitting advancement of the first assembly sheet.
Dependencies are inferred from the claim text.