Systems and methods for monitoring and controlling an absorbent article converting line

A method for manufacturing an absorbent article, the method comprising the steps of:

• providing a first line scan camera comprising a linear array of pixel data and defining a first linear field of view;
• providing a second line scan camera comprising a linear array of pixel data and defining a second linear field of view;
• providing an analyzer selected from the group consisting of:
• a field programmable gate array, an application specific integrated circuit, and graphical processing unit;
• arranging the first and second line scan cameras such that the first and second linear fields of view extend in a machine direction;
• operating an illumination source to define an illumination field that illuminates the first and second linear fields of view;
• providing a substrate comprising a discrete component having a width in the cross direction, the substrate further comprising a first lateral side edge and a second lateral side edge separated from the first lateral side edge to define a length in the machine direction;
• advancing the substrate in the machine direction such that the first and second lateral side edges travel through the first linear field of view, and such that the first and second lateral side edges travel through the second linear field of view;
• communicating a first set of grayscale values of pixels from the linear array of pixel data from the first and second line scan cameras to the analyzer;
• and
• communicating a second set of grayscale values of pixels from the linear array of pixel data from the first and second line scan cameras to the analyzer;
• and
• determining an orientation of the substrate relative to the machine direction based on the first and second sets of grayscale values of at least two pixels.

An apparatus for monitoring a substrate advancing along a converting apparatus in a machine direction, the substrate comprising a first surface and an opposing second surface, the substrate further comprising a first longitudinal side edge and a second longitudinal side edge separated from the first longitudinal side edge to define a width in a cross direction, the apparatus comprising:

• a communication network;
• an analyzer connected with the communication network, the analyzer comprising a linear array of pixel data and defining a linear field of view extending in the machine direction, wherein the analyzer is selected from the group consisting of:
• a field programmable gate array, an application specific integrated circuit, and graphical processing unit;
• a line scan camera connected with the communication network, the line scan camera comprising a linear array of pixel data and defining a linear field of view, wherein the line scan camera is arranged such that the linear field of view extends in the machine direction;
• an illumination source defining an illumination field that illuminates the linear field of view;
• and
• wherein the analyzer is configured to determine a position of the first longitudinal side edge of the substrate based on based on a set of grayscale values of pixels from the linear array of pixel data from the analyzer.