Autosetpoint registration control system and method associated with a web converting manufacturing process

An automatic registration set point control system, suitable for use in connection with a high speed web converting manufacturing process for producing a composite product from a sequential addition of component parts during a production run of composite products, said system comprising:

• a communication network;
• an inspection system for automatically inspecting a component part of the composite product produced during the production run, said inspection system generating an image of the component part and determining from the generated image an inspection parameter indicative of a characteristic of the inspected component part, said inspection system determining a set point parameter as a function of the inspection parameter;
• and
• a registration control system obtaining the set point parameter via the communication network and controlling a registration of the component part relative to another component part as a function of the obtained set point parameter.

An automatic registration set point control system, suitable for use in connection with a high speed web converting manufacturing process for producing a composite product from a sequential addition of component parts during a production run of composite products, said system comprising:

• a communication network;
• an inspection system for automatically inspecting a component part of the composite product produced during the production run, said inspection system generating an image of the component part and providing from the generated image an inspection parameter indicative of a characteristic of the inspected component part;
• and
• a registration control system obtaining the inspection parameter via the communication network and determining a registration set point adjustment of the component part relative to another component part as a function of the inspection parameter.

An automatic registration set point control method, said method being suitable for use in connection with a high speed web converting process for manufacturing a composite article from a sequential addition of component parts during a production run of composite articles, said method comprising:

• detecting a placement of a first component part using a first sensor, said first sensor operating at a first set point to trigger a registration control action associated with the placement of the first component part;
• generating an image indicating a position of a component subsequent to the registration control action using a second sensor positioned apart from the first sensor;
• comparing to a target the position of the component indicated by the generated image;
• and
• selectively adjusting the first set point subsequent to the registration control action as a function of a difference between the position of the component indicated by the generated image and the target.

An automatic control method suitable for use in connection with a high speed web converting process for manufacturing a composite article from a sequential addition of component parts during a production run of composite articles, said method comprising:

• detecting a placement of a first component part using a first sensor, said first sensor operating at a first set point to trigger a length control action as a function of the detected placement of the first component;
• generating an image indicating a position of a component using a second sensor positioned to detect said position of the component subsequent to the length control action;
• comparing to a target the position of the component indicated by the generated image;
• and
• selectively adjusting the first set point subsequent to the length control action as function of a difference between the position of the component indicated by the generated image and the target.

An automatic registration set point control method, said method being suitable for use in connection with a high speed web converting manufacturing process for producing a composite article from a sequential addition of component parts during a production run of composite articles, said method comprising:

• detecting a placement of a first component part of a first composite article being produced;
• providing a first signal indicative of the placement of the first component part of the first composite article;
• generating an image indicating a placement of a second component of the first composite article being produced;
• providing from the generated image a second signal indicative of the placement of the second component of the first composite article;
• determining from the first and second signals an absolute measurement of the placement of said second component relative to said first component parts;
• comparing said absolute measurement to a target indicative of a desired relative offset between said first and second signals;
• and
• adjusting a set point controlling placement of a component of a second composite article produced subsequent to the first composite article during the production run as a function of a difference between the absolute measurement and the target such that the desired relative offset between the first and second signals is substantially achieved with respect to the second composite article.

An automatic registration method, said method being suitable for use in connection with a high speed web converting manufacturing process for producing a composite article from a sequential addition of component parts during a production run of composite articles, said method comprising:

• detecting a placement of a first component part of a first composite article being produced;
• providing a first signal indicative of the placement of the first component part of the first composite article;
• generating an image indicating a placement of a second component of the first composite article being produced;
• providing from the generated image a second signal indicative of the placement of the second component of the first composite article;
• determining from the first and second signals an absolute measurement of the placement of said second component relative to said first component part;
• comparing said absolute measurement to a target indicative of a desired relative offset between the first and second signals;
• and
• controlling placement of a component of a second composite article produced subsequent to the first composite article during the production run as a function of a difference between the absolute measurement and the target such that the desired relative offset between the first and second signals is substantially achieved with respect to the second composite article.

An automatic registration set point control system being suitable for use in connection with high speed web converting process for producing a composite absorbent article from a sequential addition of component parts during a production run of composite articles, said system comprising:

• a first sensor positioned to detect a placement of a first component part, said first sensor operating at a first set point to trigger a registration control action associated with the placement of said first component part;
• a second sensor positioned apart from the first sensor, said second sensor generating an image indicating a position of a component subsequent to the registration control action associated with the placement of the first component part, said second sensor providing an inspection parameter indicative of the position of the component;
• and
• a processor obtaining the inspection parameter and comparing said inspection parameter to a target, said processor determining an amount of adjustment to the first set point subsequent to the registration control action as a function of a difference between the inspection parameter and the target.

A control system suitable for use in connection with high speed web converting process for producing a composite absorbent article from a sequential addition of component parts during a production run of composite articles, said system comprising:

• a first sensor positioned to detect a placement of a first component part, said first sensor operating at a first set point to trigger a length control action associated with said first component part;
• a second sensor positioned apart from the first sensor, said second sensor generating an image indicating a position of a component subsequent to the length control action associated with the first component part, said second sensor providing an inspection parameter indicative of the position of the first component part;
• and
• a processor obtaining the inspection parameter and comparing said inspection parameter to a target, said processor determining an amount of adjustment to the first set point as a function of a difference between the inspection parameter and the target wherein adjusting said first set point affects the subsequent manufacture of said first component part for use in the production run.