Kimberly-clark Worldwide, Inc.

Shawn Timothy Lemery

Thomas Arthur Bett

Tanakon Ungpiyakul

Wayne Allen Bernhardt

Russell Joseph Brumm

Robert Jeffrey Giza

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.

Method of controlling cross-direction alignment in manufacturing process

Apparatus and method using vision imaging for combined short-term and long-term monitoring and control of a manufacturing operation which produces absorbent articles for absorbing body fluids. The system collects discrete real-time visual images at a rate of at least 50-400 images per minute, up to at least 1200 images per minute, provides an ongoing display of a pattern of such images, and upon occurrence of a triggering event, continues the visual display of the images while sending information representing a limited number set of real-time images to a memory storage system which receives and permanently stores the information, for future retrieval. The data is preferably received in a temporary memory device, and written from there to a second permanent memory device. While the visual images are being sent to the memory storage system, process control logic preferably analyzes the visual images in real time, and sends results signals to manufacturing control, which modifies the manufacturing operation, for example, modifying timing of a process step, shutting the process down, or culling work pieces. A second set of a second limited number of such visual images can be sent to the memory system in response to a second, optionally subsequent, triggering event and/or from a second location. After sending any set of real-time visual images to memory storage, and prior to occurrence of a next triggering event, preferably images are continually collected, received, but few or none of such images are sent to the memory storage device. Image collection is preferably synchronized with advancement of the work pieces or product, or process steps, along the manufacturing process line.

Making absorbent articles using vision imaging system

Controlling processes comprising detecting and measuring a parameter, for example presence and location of an element of a good, with at least two determinations as representations of the target parameter, transmitting signals to the computer, and processing the signals to compare the parameter to acceptable conditions. The detection can include three or more replications, optionally each for at least two parameters, optionally using at least two different methods to analyze the signals. The invention contemplates detecting and analyzing the target parameters using two or more analytical tools within the respective image to detect a given component of the product, namely two or more measurements of the parameter on a single visual image. Analytical methods can include averaging the signals, determining the number of signals of common signal duration and/or signal characteristics, computing standard deviation, modifying the signal combination to compensate for an inappropriate signal, and/or comparing the signals to a database of signal combinations. The method can automatically compute probable cause of some anomalies in the signals, develop corresponding responses, and transmit responses to process control, and thence to control devices. The methods can automatically recalibrate determinors, or automatically adjust analysis to a basis of one less determinor, and/or automatically implement back-up inspection of goods, optionally saving images for further analysis, or culling units of product. Digitized visual images represent pixels and pixel combinations. The method contemplates analyzing the pixel representations with at least two determinations of the parameter in respective at least two areas of the image, optionally for at least two parameters at respective replication sites, using software interpretation of selected areas of the visual image.

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South Ogden, UT, United States of America

Shawn Timothy Lemery