US 6,856,859 B1 · Method of controlling cross-direction alignment in manufacturing process

Abstract

Control processes control cross direction alignment of elements being assembled as work pieces on a manufacturing line fabricating preferably absorbent article products on a continuous substrate web. The method defines a manufacturing line path traversed by the work pieces, defines a reference path along the manufacturing path, and establishes the elements on the work pieces. A camera is mounted along the manufacturing line. An image window of the camera is referenced to the reference path. The camera captures full digitized visual images of work pieces. The camera is part of a vision imaging inspection and control system which inspects and evaluates images of the work pieces, including the cross-direction positions of the elements on the work pieces, against established acceptable positions relative to the reference path. When an element is out of alignment, the control system can display visual cues identifying the elements that are inconsistent with acceptable ranges. The full digitized images can be selectively stored in permanent memory, retrieved from permanent memory, and analyzed off-line. The machines are adjusted to adjust positioning of such elements, thereby directing the elements toward target positions. The invention includes step-wise computer-assisted image analysis methodology in an image analysis system linked to a computer program containing system logic, to identify problem areas of the work pieces, and to provide step-wise implementation methodology which can be implemented automatically but is sometimes implemented through human intervention, for making appropriate adjustments to the process. The invention further comprehends apparatus for implementing the above methods, including machines arrayed in a manufacturing line, control apparatus effective to control cross-direction positioning of work pieces, an image collecting system, a memory system, and an image analysis system.

Claims33

Dependent claims

A method of controlling cross-machine direction alignment of elements being assembled as work nieces on a manufacturing line, the manufacturing line including a plurality of work stations, to fabricate respective products from the respective work pieces, the method comprising:

(a) defining a machine direction manufacturing line path traversed by the work pieces as the work nieces move from work station to work station and have work performed thereon;
(b) defining a machine direction reference path extending in the direction of the machine direction manufacturing line path and referenced to machines along the manufacturing line;
(c) establishing acceptable cross-machine direction positions along the manufacturing line path and relative to the reference path, for an element to be established on respective ones of the work pieces;
(d) moving work pieces from work station to work station, and establishing the element on the respective work pieces at respective work stations;
(e) fixedly mounting a camera, as a component of a vision imaging inspection and control system, alone the manufacturing line path such that the work pieces move past the camera, the camera having an image window defined in terms of images to be captured by the camera and to be displayed by the imaging system;
(f) referencing the image window of the camera to the reference path;
(g) capturing visual images of respective work pieces moving past the camera;
and
(h) in the captured visual images, evaluating the cross-machine direction position of the element on the respective work pieces with respect to the reference path, against the established acceptable cross-machine direction positions,
wherein the reference path represents a centerline of the manufacturing line.

7 more elements

A method of controlling cross-machine direction alignment of elements being assembled as work pieces on a manufacturing line, the manufacturing line including a plurality of work stations, to fabricate respective products from the respectively work pieces, the method comprising:

(a) defining a machine direction manufacturing line path traversed by the work pieces as the work pieces move from work station to work station and have work performed thereon;
(b) defining a machine direction reference path extending in the direction of the machine direction manufacturing line path and referenced to machines along the manufacturing line;
(c) establishing acceptable cross-machine direction positions along the manufacturing line path and relative to the reference path, for an element to be established on respective ones of the work pieces;
(d) moving work pieces from work station to work station, and establishing the element on the respective work pieces at respective work stations;
(e) fixedly mounting a camera, as a component of a vision imaging inspection and control system, along the manufacturing line path such that the work pieces move past the camera, the camera having an image window defined in terms of images to be captured by the camera and to be displayed by the imaging system;
(f) referencing the image window of the camera to the reference path;
(g) capturing visual images of respective work pieces moving past the camera;
and
(h) in the captured visual images, evaluating the cross-machine direction position of the element on the respective work pieces with respect to the reference path, against the established acceptable cross-machine direction positions,
including capturing full digitized visual images of the respective work pieces,
the visual image inspection and control system providing a visual display of respective ones of the work pieces, and providing visual cues identifying elements that are outside acceptable ranges for the respective parameters.

8 more elements

(a) defining a machine direction manufacturing line path traversed by the work pieces as the work pieces move from work station to work station and have work performed thereon;
(b) defining a machine direction reference path extending in the direction of the machine direction manufacturing line path and referenced to machines along the manufacturing line;
(c) establishing acceptable cross-machine direction positions along the manufacturing line path and relative to the reference path, for an element to be established on respective ones of the work pieces;
(d) moving work pieces from work station to work station, and establishing the element on the respective work pieces at respective work stations;
(e) fixedly mounting a camera as a component of a vision imaging inspection and control system, along the manufacturing line path such that the work pieces move past the camera, the camera having an image window defined in terms of images to be captured by the camera and to be displayed by the imaging system;
(f) referencing the image window of the camera to the reference path;
(g) capturing visual images of respective work pieces moving past the camera;
and
(h) in the captured visual images, evaluating the cross-machine direction position of the element on the respective work pieces with respect to the reference path, against the established acceptable cross-machine direction positions,
including storing, in permanent memory, full digitized visual image representation of selected ones of the work pieces, retrieving from permanent storage a full digitized visual image representation of one of the stored full digitized visual images, and conducting off-line image analysis of the retrieved image,
including implementing a computer-assisted image analysis methodology to assist a system operator in analyzing cross-machine direction positioning of respective elements of the work piece,
including implementing step-wise computer analysis methodology to assist the system operator in making adjustments to direct the process toward alignment of the respective elements along the reference path.

9 more elements

A method of controlling cross-machine direction alignment of elements being assembled as work pieces on a manufacturing line the manufacturing line including a plurality of work stations, to fabricate respective products from the respective work pieces, the method comprising:

(a) defining a machine direction manufacturing line path traversed by the work pieces as the work pieces move from work station to work station and have work performed thereon;
(b) defining a machine direction reference path extending in the direction of the machine direction manufacturing line path and referenced to machines along the manufacturing line;
(c) establishing acceptable cross-machine direction positions along the manufacturing line path and relative to the reference path, for an element to be established on respective ones of the work pieces;
(d) moving work pieces from work station to work station, and establishing the element on the respective work pieces at respective work stations;
(e) fixedly mounting a camera, as a component of a vision imaging inspection and control system, along the manufacturing line path such that the work pieces move past the camera, the camera having an image window defined in terms of images to be captured by the camera and to be displayed by the imaging system;
(f) referencing the image window of the camera to the reference path;
(g) capturing visual images of respective work pieces moving past the camera;
and
(h) in the captured visual images, evaluating the cross-machine direction position of the element on the respective work pieces with respect to the reference path, against the established acceptable cross-machine direction positions,
including storing in permanent memory, full digitized visual images of selected ones of the work pieces, retrieving from permanent storage a full digitized visual image representation of one of the stored full digitized visual images, and conducting off-line image analysis of the retrieved image,
including implementing a computer-assisted image analysis methodology to assist a system operator in analyzing cross-machine direction positioning of respective elements of the work piece,
including implementing an image analysis system linked to a computer program containing system logic effective to identify problem areas of the work piece and to then provide step-wise implementation methodology for making appropriate adjustments to the process, to thereby direct the elements along the reference path consistent with acceptable cross-direction positioning of the respective elements.

9 more elements

(a) defining a machine direction manufacturing line path traversed by the work pieces as the work pieces move from work station to work station and have work performed thereon;
(b) defining a machine direction reference path extending in the direction of the machine direction manufacturing line path and referenced to machines along the manufacturing line;
(c) establishing acceptable cross-machine direction positions along the manufacturing line path and relative to the reference path, for an element to be established on respective ones of the work pieces;
(d) moving work pieces from work station to work station, and establishing the element on the respective work pieces at respective work stations;
(e) fixedly mounting a camera, as a component of a vision imaging inspection and control system, along the manufacturing line path such that the work pieces move past the camera, the camera having an image window defined in terms of images to be captured by the camera and to be displayed by the imaging system:
(f) referencing the image window of the camera to the reference path;
(g) capturing visual images of respective work pieces moving past the camera;
and
(h) in the captured visual images, evaluating the cross-machine direction position of the element on the respective work pieces with respect to the reference path, against the established acceptable cross-machine direction positions,
the camera being mounted at a first work station, and including fixedly mounting a second camera at a second work station, and capturing second visual images of the respective work pieces moving past the second camera, and using the composite of the first and second visual images to evaluate cross-machine direction positioning of the respective elements with respect to the reference path.

7 more elements

A method of controlling cross-machine direction alignment of elements being assembled as work pieces on a manufacturing line, the manufacturing line including a plurality of work stations, to fabricate respective absorbent article products from the respective work pieces, the method comprising:

(a) defining a machine direction manufacturing line path traversed by the absorbent article work pieces as the work pieces move from work station to work station and have work performed thereon;
(b) defining a machine direction reference path extending in the direction of the machine direction manufacturing line path and referenced to machines along the manufacturing line;
(c) establishing acceptable cross-machine direction positions along the manufacturing line path and relative to the reference path, for an element to be established an respective ones of the absorbent article work pieces;
(d) moving absorbent article work pieces from work station to work station, and establishing the element on of the respective absorbent article work pieces at respective work stations;
(e) fixedly mounting a camera, as a component of a vision imaging inspection and control system, along the manufacturing line path such that the absorbent article work pieces move past the camera, the camera having an image window defined in terms of images to be captured by the camera and to be displayed by the imaging system;
(f) referencing the image window of the camera to the reference path;
(g) capturing visual images of respective absorbent article work pieces moving past the camera;
and
(h) in the captured visual images, evaluating the cross-machine direction position of the element on the respective absorbent article work pieces with respect to the reference path, against the established acceptable cross-machine direction positions,
wherein the reference path represents a centerline of the manufacturing line.

7 more elements

A method of controlling cross-machine direction alignment of elements being assembled as work pieces on a manufacturing line, the manufacturing line including a plurality of work stations, to fabricate respective absorbent article products from the respective work pieces, the method comprising:

(a) defining a machine direction manufacturing line path traversed by the absorbent article work pieces as the work pieces move from work station to work station and have work performed thereon;
(b) defining a machine direction reference path extending in the direction of the machine direction manufacturing line path and referenced to machines along the manufacturing line;
(c) establishing acceptable cross-machine direction positions alone the manufacturing line path and relative to the reference path, for an element to be established on respective ones of the absorbent article work pieces;
(d) moving absorbent article work pieces from work station to work station, and establishing the element on of the respective absorbent article work pieces at respective work stations;
(e) fixedly mounting a camera, as a component of a vision imaging inspection and control system, along the manufacturing line path such that the absorbent article work pieces move past the camera, the camera having an image window defined in terms of images to be captured by the camera and to be displayed by the imaging system;
(f) referencing the image window of the camera to the reference path;
(g) capturing visual images of respective absorbent article work pieces moving past the camera;
and
(h) in the captured visual images, evaluating the cross-machine direction position of the element on the respective absorbent article work pieces with respect to the reference path, against the established acceptable cross-machine direction positions,
including capturing full digitized visual images of the respective work pieces,
the visual image inspection and control system providing a visual display of respective ones of the work pieces, and providing visual cues identifying elements that are outside acceptable ranges for the respective parameters.

8 more elements

A method of controlling cross-machine direction alignment of elements being assembled as work pieces on a manufacturing line, the manufacturing line including a plurality of work stations, to fabricate respective absorbent article products from the respective work pieces, the method comprising:

(a) defining a machine direction manufacturing line path traversed by the absorbent article work pieces as the work pieces move from work station to work station and have work performed thereon;
(b) defining a machine direction reference path extending in the direction of the machine direction manufacturing line path and referenced to machines along the manufacturing line;
(c) establishing acceptable cross-machine direction positions along the manufacturing line path and relative to the reference path, for an element to be established on respective ones of the absorbent article work pieces;
(d) moving absorbent article work pieces from work station to work station, and establishing the element on of the respective absorbent article work pieces at respective work stations;
(e) fixedly mounting a camera, as a component of a vision imaging inspection and control system, along the manufacturing line path such that the absorbent article work pieces move past the camera, the camera having an image window defined in terms of images to be captured by the camera and to be displayed by the imaging system;
(f) referencing the image window of the camera to the reference path;
(g) capturing visual images of respective absorbent article work pieces moving past the camera;
and
(h) in the captured visual images, evaluating the cross-machine direction position of the element on the respective absorbent article work pieces with respect to the reference path, against the established acceptable cross-machine direction positions,
including storing, in permanent memory, full digitized visual images of selected ones of the work pieces, retrieving from permanent storage a full digitized visual image representation of one of the stored full digitized visual images, and conducting off-line image analysis of the retrieved image,
including implementing a computer-assisted image analysis methodology to assist a system operator in analyzing cross-machine direction positioning of respective elements of the work piece,
including implementing step-wise computer analysis methodology to assist the system operator in making adjustments to direct the process toward alignment of the respective elements along the reference path.

9 more elements

A method of controlling cross-machine direction alignment of elements being assembled as work pieces on a manufacturing line, the manufacturing line including a plurality of work stations, to fabricate respective absorbent article products from the respective work pieces, the method comprising:

(a) defining a machine direction manufacturing line path traversed by the absorbent article work pieces as the work pieces move from work station to work station and have work performed thereon;
(b) defining a machine direction reference path extending in the direction of the machine direction manufacturing line path and referenced to machines alone the manufacturing line;
(c) establishing acceptable cross-machine direction positions along the manufacturing line path and relative to the reference path, for an element to be established on respective ones of the absorbent article work pieces;
(d) moving absorbent article work pieces from work station to work station, and establishing the element on of the respective absorbent article work pieces at respective work stations;
(e) fixedly mounting a camera, as a component of a vision imaging inspection and control system, along the manufacturing line path such that the absorbent article work pieces move past the camera, the camera having an image window defined in terms of images to be captured by the camera and to be displayed by the imaging system;
(f) referencing the image window of the camera to the reference path;
(g) capturing visual images of respective absorbent article work pieces moving past the camera;
and
(h) in the captured visual images, evaluating the cross-machine direction position of the element on the respective absorbent article work pieces with respect to the reference path, against the established acceptable cross-machine direction positions,
including storing, in permanent memory, full digitized visual images of selected ones of the work pieces, retrieving from permanent storage a full digitized visual image representation of one of the stored full digitized visual images, and conducting off-line image analysis of the retrieved image,
including implementing a computer-assisted image analysis methodology to assist a system operator in analyzing cross-machine direction positioning of respective elements of the work piece,
including implementing an image analysis system linked to a computer program containing system logic effective to identify problem areas of the work piece and to then provide step-wise implementation methodology for making appropriate adjustments to the process, to thereby direct the elements along the reference path consistent with acceptable cross-direction positioning of the respective elements.

9 more elements

Dependencies are inferred from the claim text.

Method of controlling cross-direction alignment in manufacturing process

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Method of controlling cross-direction alignment in manufacturing process

Life of this patent

Abstract

Claims33