JP2023157667A - Absorbent product manufacturing apparatus, absorbent product manufacturing method, and program - Google Patents

Abstract

To early identify a defect in upstream processes of absorbent product manufacturing.SOLUTION: An absorbent product manufacturing apparatus comprises: a stacking unit that stacks absorbent bodies in an absorbent product from crushed and/or fibrillated materials; a first acquisition unit that acquires first information related to manufacturing of the absorbent product from a sensor provided in at least the stacking unit; a second acquisition unit that acquires second information related to an article of the absorbent product in a manufacturing line of the absorbent product; a memory unit that stores the first information and the second information in association with each other; a determination unit that based on the first information and the second information, determines presence or absence of an abnormality at least in the stacking unit; and an output unit that outputs a determination result by the determination unit.SELECTED DRAWING: Figure 11

Description

The present invention relates to an absorbent article manufacturing apparatus, an absorbent article manufacturing method, and a program.

Conventionally, in manufacturing equipment that manufactures absorbent articles, product data and equipment data are associated, and when an abnormality occurs in the product, at least one of the product data and equipment data associated with the product determined to be abnormal is linked. There are known techniques for identifying the manufacturing process that caused the product abnormality.

Japanese Patent Application Publication No. 2018-129030

However, the above-described techniques have room for further improvement in terms of early identification of defects in upstream processes in the manufacture of absorbent articles.

For example, in the above-mentioned technique, an abnormality is detected by a sensor provided downstream from the process of manufacturing the absorbent body in the absorbent article. For this reason, even if there is a defect in the manufacturing state of the absorber itself, there is room for other causes of abnormality to occur in the process leading up to the sensor, and it is difficult to directly identify the defect in the manufacturing state of the absorber. was difficult.

The present application has been made in view of the above, and aims to quickly identify defects in upstream processes in the manufacture of absorbent articles.

An apparatus for manufacturing an absorbent article according to the present application includes a laminating section that laminates absorbent bodies in the absorbent article from pulverized and/or defibrated materials, and a sensor provided at least in the laminating section to manufacture the absorbent article. a first acquisition unit that acquires first information that is information about the product, and a second acquisition unit that acquires second information that is information about the product of the absorbent article in the manufacturing line of the absorbent article; a storage unit that stores the first information and the second information in association with each other; a determination unit that determines whether or not there is an abnormality in at least the laminated portion based on the first information and the second information; The apparatus is characterized by comprising an output section that outputs a determination result by the determination section.

According to one aspect of the embodiment, a problem in an upstream process in manufacturing an absorbent article can be identified at an early stage.

FIG. 1 is a schematic side view showing an example of the configuration of a manufacturing line according to an embodiment. FIG. 2 is a schematic diagram of a diaper manufactured on a manufacturing line. FIG. 3 is a schematic front view showing a configuration example of the laminated section according to the embodiment. FIG. 4 is a schematic side view showing a configuration example of the laminated section according to the embodiment. FIG. 5 is an explanatory diagram of sensor positions in the laminated portion according to the embodiment. FIG. 6 is an explanatory diagram of the flow of intake air in the laminated portion according to the embodiment. FIG. 7 is a diagram showing an example of arrangement of plates forming recesses. FIG. 8 is a schematic plan view of the plate. FIG. 9 is a diagram showing an example of an image captured at a downstream position of the laminated section. FIG. 10 is a block diagram illustrating a configuration example of a manufacturing system according to an embodiment. FIG. 11 is a block diagram illustrating a configuration example of a monitoring device according to an embodiment. FIG. 12 is a diagram showing an example of sensor information stored in the acquired information DB. FIG. 13 is a diagram showing an example of plate information stored in the acquired information DB. FIG. 14 is a diagram showing an example of product information stored in the acquisition information DB. FIG. 15 is an explanatory diagram of an example of linking manufacturing information and product information. FIG. 16 is a diagram (part 1) showing a specific example of analysis processing. FIG. 17 is a diagram (part 2) showing a specific example of the analysis process. FIG. 18 is a diagram (part 3) showing a specific example of the analysis process. FIG. 19 is a flowchart showing a processing procedure executed by the monitoring device according to the embodiment. FIG. 20 is a diagram showing an example of the hardware configuration.

From the description of this specification and the attached drawings, at least the following matters will become clear.

In an apparatus for producing an absorbent article, a laminating section that laminates an absorbent body in the absorbent article from pulverized and/or defibrated materials, and information regarding the manufacturing of the absorbent article from a sensor provided at least in the laminating section. a first acquisition unit that acquires certain first information; a second acquisition unit that acquires second information that is information regarding the product of the absorbent article in the manufacturing line of the absorbent article; a storage unit that stores the information and the second information in association with each other; a determination unit that determines the presence or absence of an abnormality in at least the laminated portion based on the first information and the second information; and the determination unit An apparatus for manufacturing an absorbent article, comprising: an output unit that outputs a determination result according to the method.

According to such an apparatus for manufacturing an absorbent article, it is possible to quickly identify a problem in an upstream process in manufacturing an absorbent article.

Further, the laminated part has a rotating part that is provided in an annular shape and is rotatable around the central axis of the annular ring, and a plurality of recesses or continuous recesses are formed along the outer peripheral surface of the rotating part. A rotating drum, a suction section provided opposite to the inner circumferential surface and the outer circumferential surface of the rotary section, and an intake air flow through a pipe connected to the suction section behind the rotating drum, into the recess. On the other hand, it includes an intake fan that sucks the material to stack the absorbers and separates the stacked absorbers from the recess, and a plurality of the sensors are provided in the piping.

According to such an absorbent article manufacturing apparatus, it is possible to obtain high-quality sensor data that is less susceptible to static electricity and vibrations regarding the intake air flow in the laminated portion.

Further, a plurality of pipings are connected to the suction section, and a plurality of sensors are provided on each straight portion of the piping.

According to such an absorbent article manufacturing apparatus, it is possible to stably acquire sensor data for each pipe regarding the intake air flow in the laminated portion.

Further, the first information includes information regarding the pressure and/or flow rate of the intake air flowing through the piping.

According to such an absorbent article manufacturing apparatus, it is possible to analyze the state of the laminated part based on the pressure and/or flow rate of the intake air regarding the intake flow in the laminated part, and to determine whether there is an abnormality in the laminated part. Become.

Further, the sensor is at least one of a pressure sensor, a flow rate sensor, and a flow rate sensor.

According to such an absorbent article manufacturing apparatus, the state of the laminated part is analyzed based on the pressure and/or flow rate of the intake air measured by a pressure sensor and/or a flow rate sensor, and abnormalities in the laminated part are detected. It becomes possible to determine the presence or absence of. Further, even if only a pressure sensor is used, the flow rate can be calculated by using Bernoulli's theorem.

Further, the recess is formed by a replaceable plate, and the first information includes information regarding the plate.

According to such an absorbent article manufacturing device, it is possible to determine whether or not there is an abnormality in each plate, and when it is determined that there is an abnormality, it is possible to take measures to deal with the abnormality in each plate. becomes.

Further, the information regarding the plate includes at least one of information regarding identification of the plate, information regarding previous maintenance, and information regarding next replacement.

According to such an absorbent article manufacturing apparatus, a plate can be identified based on information regarding plate identification, and what to do with the identified plate can be determined based on information regarding previous maintenance and information regarding next replacement. becomes possible.

Further, the second information includes information regarding the finished product and/or the semi-finished product.

According to such an absorbent article manufacturing apparatus, it is possible to analyze the state of the laminated portion based on information regarding not only the finished product but also the semi-finished product, and determine whether or not there is an abnormality in the laminated portion.

The absorbent body further includes an image sensor provided downstream of the laminated portion in the manufacturing line, and the second information includes information regarding an image showing the state of the absorbent body captured by the image sensor.

According to such an absorbent article manufacturing apparatus, the distribution state of the material in the absorber and the lamination state of the absorber are detected based on an image showing the state of the absorber at a position downstream of the laminated part, and the detection result is detected. It becomes possible to analyze the state of the laminated portion based on this and determine whether or not there is an abnormality in the laminated portion.

Further, the material includes at least one of pulp, synthetic fiber, and polymer absorbent material, and the second information includes information regarding the material.

According to such an absorbent article manufacturing apparatus, it is possible to analyze the state of the laminated portion based on information regarding the material of the absorber and determine whether there is an abnormality in the laminated portion.

The apparatus further includes a temperature sensor and/or a humidity sensor, and the first information includes information regarding the temperature measured by the temperature sensor and/or information regarding the humidity measured by the humidity sensor.

According to such an absorbent article manufacturing device, it is possible to analyze the state of the laminated portion based on information about the surrounding environment of the manufacturing line, such as temperature and humidity, and determine whether there is an abnormality in the laminated portion. .

Below, an example of a manufacturing apparatus, a manufacturing method, and a form for implementing a program (hereinafter referred to as "embodiment") related to manufacturing an absorbent article will be described in detail with reference to the drawings. Note that this embodiment does not limit the manufacturing apparatus, manufacturing method, and program related to manufacturing the absorbent article. In addition, in the following embodiments, the same parts are given the same reference numerals, and redundant explanations will be omitted.

[Embodiment]
[1. Production line configuration example]
First, a configuration example of a manufacturing line PL for manufacturing absorbent articles will be described with reference to FIGS. 1 and 2. FIG. 1 is a schematic side view showing an example of the configuration of a manufacturing line PL according to an embodiment. FIG. 2 is a schematic diagram of a diaper manufactured on the manufacturing line PL. At least a portion of the manufacturing line PL is included in a manufacturing apparatus 50 according to an embodiment described later.

The manufacturing line PL according to the embodiment is a serialized manufacturing process for manufacturing absorbent articles. Absorbent articles are, for example, diapers, sanitary napkins, and urine absorbing pads. In addition, below, description will proceed using the case where a diaper D is manufactured as an absorbent article as a main example.

In the production line PL, a plurality of processing processes are performed in which a continuous sheet (which may also be referred to as a "continuous web"), which is a continuous body from which the diaper D is processed, is processed at different positions. Note that "processing" as used herein refers to all means applied to the continuous web until one piece of diaper D is finally manufactured.

Therefore, traces of "processing" such as sequentially arranging absorbers on a continuous web, forming a continuous web into a predetermined shape, and cutting it piece by piece end up on each piece of diaper D. In addition to those that remain on a single piece of diaper D, no trace of the "processing" will ultimately remain on a single piece of diaper D, such as material splicing processing that connects materials such as continuous webs so that they do not break. Also included.

In addition, below, the width direction of the production line PL (the direction penetrating the paper surface of FIG. 1) will be referred to as the "CD direction", and of the two directions perpendicular to the CD direction, the vertical direction will be referred to as the "vertical direction". The horizontal direction is sometimes referred to as the "front-back direction."

As shown in FIG. 1, the production line PL includes a core wrap conveyance path R1, an absorbent body conveyance path R2, a fastening tape conveyance path R3, a top sheet conveyance path R4, a target tape conveyance path R5, and a backsheet conveyance path R2. A path R6 and a base sheet conveyance path R7 are included.

Each of the transport routes R1 to R7 is provided with a transport device (not shown). The conveyance device includes a belt conveyor, conveyance rollers, and the like. The belt conveyor is, for example, a normal belt conveyor whose conveyance surface is an endless belt that rotates around the belt, or a suction belt conveyor that has a suction function on the outer peripheral surface of the endless belt.

In the core wrap conveyance path R1, the core wrap sheet Cs is unwound from the material coil 201 in which the core wrap sheet Cs is wound into a coil shape. That is, in the core wrap conveyance path R1, the core wrap sheet Cs, which is a continuous sheet, is conveyed. The core wrap sheet Cs is, for example, a liquid-permeable sheet member such as tissue paper or nonwoven fabric.

In the absorbent conveyance route R2, the absorbent body Ab is placed on the core wrap sheet Cs conveyed from the core wrap conveyance route R1. The absorbent Ab is a liquid absorbent material, and is, for example, a laminate in which pulp fibers and superabsorbent polymers (SAP) are mixed and laminated.

The absorbent bodies Ab are laminated in a lamination section 100 provided on the production line PL. The stacking section 100 includes a crusher 101, a spreader 102, a rotating drum 103, and a hood Fd. The pulverizer 101 uses a rotary blade to pulverize and/or defibrate pulp material Pw drawn from a pulp material (not shown) to generate pulp fibers, and sends the pulp fibers into the hood Fd in an air stream.

The spreader 102 spreads SAP into the hood Fd at a predetermined period. The hood Fd has one end connected to the crusher 101 side, and the other end connected to the rotating drum 103 side so as to cover a part of the outer peripheral surface of the rotating drum 103. The pulp fibers and SAP sent into the hood Fd are mixed by a multiphase flow generated within the hood Fd.

The rotating drum 103 laminates the absorbent material Ab from the pulp fibers and SAP mixed in the hood Fd while rotating around a rotation axis along the CD direction, and places the absorbent material Ab on the core wrap sheet Cs.

The rotating drum 103 has a plurality of recesses 103a formed along the rotation direction on its outer peripheral surface. The recess 103a is formed so that the absorbent body Ab placed on the core wrap sheet Cs has a substantially rectangular shape in plan view. Note that the recesses 103a may be provided not only intermittently but also continuously.

The absorbent Ab is layered on the bottom surface of the recess 103a by sucking the pulp fibers and SAP mixed in the hood Fd. Further, while rotating, the rotating drum 103 removes the absorbent material Ab stacked in the recessed portion 103a from the recessed portion 103a and transfers it to the absorbent transport path R2, thereby placing the absorbent material Ab on the core wrap sheet Cs. . As a result, a plurality of absorbent bodies Ab are placed in line on the core wrap sheet Cs along the front-rear direction.

Note that the configuration for realizing suction and transfer in the laminated portion 100 will be described later using FIGS. 3 to 8 and the like.

Further, a press device 202 is provided on the absorbent body conveyance path R2. The press device 202 includes a pair of press rolls 202a and 202b. The press rolls 202a and 202b each rotate around a rotation axis along the CD direction. Further, the press rolls 202a and 202b sandwich and press the absorbent body Ab passing between them from above and below.

Furthermore, a cutting device 203 is provided downstream of the press device 202. The cutting device 203 cuts the core wrap sheet Cs on which the absorbent body Ab is placed. The cutting device 203 includes a cutter roll 203a and an anvil roll 203b.

The cutter roll 203a rotates around a rotation axis along the CD direction. The cutter roll 203a is provided with a cutter blade along the rotation axis direction. The anvil roll 203b rotates around a rotation axis along the CD direction.

The cutting device 203 cuts the core wrap sheet Cs on which the absorbent body Ab is placed by pinching it with a cutter roll 203a and an anvil roll 203b. Note that the cutting device 203 cuts the core wrap sheet Cs at a position between adjacent absorbent bodies Ab.

In the absorbent transport path R2, the core wrap sheet Cs cut by the cutting device 203 is transported forward.

In the fastening tape conveyance path R3, the fastening tape Ft1, which is a continuous sheet, is conveyed. In the fastening tape conveyance route R3, the adhesive is applied to the fastening tape Ft1 by the adhesive application device 204.

In the top sheet conveyance path R4, the top sheet Ts is unwound from the material coil 205 in which the top sheet Ts is wound into a coil shape. That is, the top sheet Ts, which is a continuous sheet, is transported in the top sheet transport path R4. The top sheet Ts is a sheet member having liquid permeability, and is, for example, a nonwoven fabric containing thermoplastic resin fibers such as polyethylene and polypropylene.

Further, a slip cut device 206 is provided on the top sheet conveyance path R4. The slip cut device 206 cuts the fastening tape Ft1 conveyed through the fastening tape conveyance path R3. The slip cut device 206 includes a cutter roll 206a and an anvil roll 206b.

The cutter roll 206a rotates around a rotation axis along the CD direction. The cutter roll 206a is provided with a cutter blade (not shown) that cuts the continuous sheet fastening tape Ft1 into cut-shaped fastening tapes Ft2. A plurality of cutter blades are provided in the rotation direction.

The anvil roll 206b adsorbs and holds the continuous fastening tape Ft1 coated with adhesive. The anvil roll 206b rotates around a rotation axis along the CD direction. The anvil roll 206b is provided with a receiving blade (not shown) that faces the cutter blade of the cutter roll 206a.

The slip cut device 206 adsorbs a continuous sheet of fastening tape Ft1 coated with adhesive with an anvil roll 206b, cuts the continuous sheet of fastening tape Ft1 with a cutter roll 206a, and generates a cut-shaped fastening tape Ft2. .

The slip cut device 206 adsorbs the fastening tape Ft2 cut into single pieces with an anvil roll 206b, and conveys it to a position facing the top sheet Ts.

Furthermore, a temporary press roll 207 is provided below the anvil roll 206b on the top sheet conveyance path R4. The temporary press roll 207 is provided so as to face the anvil roll 206b with the top sheet Ts in between.

The temporary press roll 207 rotates around a rotation axis along the CD direction. The temporary press roll 207 presses the fastening tape Ft2 adsorbed onto the anvil roll 206b toward the anvil roll 206b at the timing when the fastening tape Ft2 is conveyed above the top sheet Ts. Thereby, the top sheet Ts which is a continuous body is pressed against the anvil roll 206b, and the fastening tape Ft2 is adhered to the top sheet Ts by the adhesive applied to the fastening tape Ft2. Thereby, the fastening tape Ft2 is temporarily fixed to the top sheet Ts.

Further, the main press device 208 is provided on the top sheet conveyance path R4. The main press device 208 is provided on the downstream side of the temporary press roll 207 in the transport direction of the top sheet Ts on the top sheet transport path R4.

This press device 208 permanently fixes the fastening tape Ft2 temporarily fixed to the top sheet Ts. This press device 208 sandwiches the top sheet Ts to which the fastening tape Ft2 is temporarily fixed between a pair of rolls, and permanently fixes the fastening tape Ft2 to the top sheet Ts.

Each roll rotates around a rotation axis along the CD direction. One of the pair of rolls reciprocates toward the other roll. That is, the distance between the pair of rolls can be changed.

Furthermore, an adhesive coating device 209 is provided on the top sheet conveyance path R4. The adhesive application device 209 is provided downstream of the main press device 208 in the transport direction of the top sheet Ts. The adhesive application device 209 applies adhesive to the top sheet Ts to which the fastening tape Ft2 is permanently fixed. The adhesive application device 209 applies adhesive to the non-skin side of the top sheet Ts.

The target tape Tt1, which is a continuous sheet, is transported on the target tape transport path R5. In the target tape transport path R5, the adhesive coating device 210 applies adhesive to the target tape Tt1.

In the backsheet conveyance path R6, the backsheet Bs is unwound from the material coil 211 in which the backsheet Bs is wound into a coil shape. That is, in the backsheet conveyance path R6, the backsheet Bs, which is a continuous sheet, is conveyed. The back sheet Bs is a sheet member having liquid impermeability, and is, for example, a thermoplastic resin film such as polyethylene.

Further, a slip cut device 212 is provided on the back sheet conveyance path R6. The slip cut device 212 cuts the target tape Tt1 conveyed along the target tape conveyance path R5. The slip cut device 212 includes a cutter roll 212a and an anvil roll 212b.

The cutter roll 212a rotates around a rotation axis along the CD direction. The cutter roll 212a is provided with a cutter blade (not shown) that cuts the continuous sheet target tape Tt1 into cut-shaped target tapes Tt2. A plurality of cutter blades are provided in the rotation direction.

The anvil roll 212b attracts and holds a continuous target tape Tt1 coated with an adhesive. The anvil roll 212b rotates around a rotation axis along the CD direction. The anvil roll 212b is provided with a receiving blade (not shown) that faces the cutter blade of the cutter roll 212a.

The slip cut device 212 adsorbs a continuous sheet of target tape Tt1 coated with adhesive with an anvil roll 212b, and cuts the continuous sheet of target tape Tt1 with a cutter roll 212a to generate a cut-shaped target tape Tt2. .

The slip cut device 212 adsorbs the target tape Tt2 cut into single pieces with an anvil roll 212b and conveys it to a position facing the back sheet Bs.

Furthermore, a temporary press roll 213 is provided below the anvil roll 212b in the backsheet conveyance path R6. The temporary press roll 213 is provided so as to face the anvil roll 212b with the back sheet Bs in between.

The temporary press roll 213 rotates around a rotation axis along the CD direction. The temporary press roll 213 presses the target tape Tt2 attracted to the anvil roll 212b toward the anvil roll 212b at the timing when the target tape Tt2 is conveyed above the back sheet Bs. As a result, the backsheet Bs, which is a continuous body, is pressed against the anvil roll 212b, and the target tape Tt2 is adhered to the backsheet Bs by the adhesive applied to the target tape Tt2. Thereby, the target tape Tt2 is temporarily fixed to the back sheet Bs.

Further, the main press device 214 is provided on the backsheet conveyance path R6. The main press device 214 is provided downstream of the temporary press roll 213 in the conveyance direction of the backsheet Bs on the backsheet conveyance path R6.

The main press device 214 permanently fixes the target tape Tt2 temporarily fixed to the back sheet Bs. This press device 214 sandwiches the backsheet Bs to which the target tape Tt2 is temporarily fixed between a pair of rolls, and permanently fixes the target tape Tt2 to the backsheet Bs.

Each roll rotates around a rotation axis along the CD direction. One of the pair of rolls reciprocates toward the other roll. That is, the distance between the pair of rolls can be changed.

Further, an adhesive coating device 215 is provided on the backsheet conveyance path R6. The adhesive application device 215 is provided downstream of the main press device 214 in the conveyance direction of the backsheet Bs. The adhesive application device 215 applies adhesive to the back sheet Bs to which the target tape Tt2 is permanently fixed. The adhesive application device 215 applies adhesive to the skin side of the backsheet Bs.

The absorbent body Ab conveyed by the above-described absorbent body conveyance path R2, the topsheet Ts conveyed by the topsheet conveyance path R4, and the backsheet Bs conveyed by the backsheet conveyance path R6 join together at the merging position Mp.

Specifically, at the merging position Mp, the backsheet Bs of the continuous sheet joins from the non-skin side of the absorbent body Ab, and the top sheet Ts of the continuous sheet joins from the skin side of the absorbent body Ab. Since the top sheet Ts and the back sheet Bs are each coated with an adhesive, the top sheet Ts, the absorbent Ab, and the back sheet Bs are joined and integrated by the adhesive, and the base sheet of the continuous sheet is formed. BMs are generated. In the base sheet BMs, the absorbers Ab are continuously arranged at a product pitch P corresponding to the length of one piece of the diaper D in the front-rear direction.

Note that in FIG. 1, the base sheet BMs on the downstream side of the joining position Mp in the conveyance direction of the base sheet BMs is shown in a state where the top sheet Ts, the absorbent body Ab, and the back sheet Bs are spaced apart. , in fact they are joined together.

In the base sheet conveyance path R7, the base sheet BMs is conveyed. A leg hole cutting device 216 is provided on the base sheet conveyance path R7. The leg hole cutting device 216 cuts part of the base sheet BMs on both sides in the CD direction to form leg openings of the diaper D. The leg hole cutting device 216 includes a cutter roll 216a and an anvil roll 216b.

The cutter roll 216a rotates around a rotation axis along the CD direction. The cutter roll 216a is provided with a cutter blade (not shown) along the rotation direction. The cutter blade is provided in a curved shape to match the shape of the leg opening. The anvil roll 216b rotates around a rotation axis along the CD direction.

The rotation of each roll 216a, 216b in the leg hole cutting device 216 is linked to the conveyance operation of the base sheet BMs so that a leg opening is formed at a predetermined position on the base sheet BMs.

In the leg hole cutting device 216, the cutter roll 216a is movable toward the anvil roll 216b, and the distance between the cutter roll 216a and the anvil roll 216b can be changed.

Further, an end cut device 217 is provided on the base sheet conveyance path R7. The end cut device 217 is provided downstream of the leg hole cut device 216 in the conveyance direction of the base sheet BMs on the base sheet conveyance path R7.

The end cut device 217 cuts the base sheet BMs conveyed by the base sheet conveyance path R7. The end cutting device 217 includes a cutter roll 217a and an anvil roll 217b.

The cutter roll 217a rotates around a rotation axis along the CD direction. The cutter roll 217a is provided with a cutter blade (not shown) along the rotation axis direction. The anvil roll 217b rotates around a rotation axis along the CD direction.

The end cutting device 217 cuts the downstream end of the base sheet BMs at a preset position on the base sheet BMs to generate the diaper D shown in FIG. 2 .

Note that the circumferential length of the cutter roll 203a described above is set to be equal to the length of the product pitch P, which is the length of one piece of the diaper D shown in FIG. Therefore, when the cutter roll 203a rotates once, the absorbent body Ab is conveyed by an amount corresponding to the length of the product pitch P, for example.

The manufactured diaper D then undergoes an inspection process including, for example, a human visual inspection, and then is transferred to the final shipping process. Furthermore, some existing technologies attempt to identify defects in the production line PL at an early stage by inspecting the diaper D, which is still a semi-finished product, each time, for example, between each processing step on the production line PL.

However, as already mentioned, there is room for further improvement in the existing technology in terms of early identification of defects in the upstream process in the manufacture of the diaper D.

For example, in the existing technology, an abnormality is detected by a sensor provided downstream from the process of manufacturing the absorbent body Ab in the diaper D, that is, the process of laminating the absorbent body Ab in the laminated section 100 shown in FIG. Therefore, even if there is a defect in the manufacturing state of the absorber Ab itself, such as the stacking state of pulp fibers and SAP, it is possible that abnormalities may occur, such as foreign matter getting mixed in in the factory during the process leading up to the sensor. There is room for these factors to be added, and it has been difficult to directly identify defects in the manufacturing state of absorber Ab.

Therefore, in the manufacturing method according to the embodiment, first information, which is information regarding the manufacturing of the diaper D, is acquired from at least the sensor provided in the laminated part 100, and second information, which is information regarding the product of the diaper D in the manufacturing line PL, is acquired. The first information and the second information are stored in association with each other. Then, based on the first information and the second information, it is determined whether or not there is an abnormality in at least the laminated portion 100, and the determination result is output.

Hereinafter, a configuration example of the manufacturing system 1 to which the manufacturing method according to the embodiment is applied will be described in detail with reference to FIG. 3 and subsequent figures.

[2. Example of configuration of manufacturing system according to embodiment]
[2-1. Example of configuration of laminated part]
First, a configuration example of the laminated section 100 according to the embodiment will be explained. FIG. 3 is a schematic front view showing a configuration example of the laminated section 100 according to the embodiment. Further, FIG. 4 is a schematic side view showing a configuration example of the laminated section 100 according to the embodiment. Moreover, FIG. 5 is an explanatory diagram of sensor positions in the laminated section 100 according to the embodiment.

Moreover, FIG. 6 is an explanatory diagram of the flow of intake air in the laminated portion 100 according to the embodiment. Moreover, FIG. 7 is a diagram showing an example of the arrangement of the plates Pt forming the recessed portion 103a. Further, FIG. 8 is a schematic plan view of the plate Pt. Further, FIG. 9 is a diagram showing an example of an image captured at a downstream position of the laminated section 100.

As shown in FIG. 3, the above-mentioned spreader 102 includes a nozzle 102a and a sensor 102b. The nozzle 102a is a spraying port for SAP. The sensor 102b is a sensor that detects the pressure or flow rate of the SAP transport flow sprayed by air transport from the spreader 102.

Moreover, the above-mentioned rotating drum 103 has a rotating part 103b. The rotating portion 103b is provided in an annular shape and rotates around the central axis of the annular ring. The above-mentioned recesses 103a are formed in plurality or continuously along the outer circumferential surface of the rotating portion 103b. Furthermore, the laminated portion 100 includes intake ports 104-A, 104-B, 104-C, 104-D, 104-E, and 104-F. The intake ports 104-A, 104-B, 104-C, 104-D, and 104-E are formed behind the rotating drum 103 so as to be arranged along the inner circumference of the rotating drum 103.

The intake ports 104-A, 104-B, 104-C, and 104-D correspond to the upper semicircular area when the rotating drum 103 is divided into two vertically using the horizontal diameter of the rotating drum 103 as a cutting line. provided at the location. The intake port 104-E is provided at a position corresponding to the lower semicircular area when divided into two.

Furthermore, the stacking section 100 further includes a transfer conveyor 105. The transfer conveyor 105 forms the above-mentioned absorbent body conveyance path R2. The intake port 104-F is provided below the rotating drum 103, specifically, at a position corresponding to the transfer position of the absorbent Ab from the rotating drum 103 to the transfer conveyor 105.

Note that, as shown in FIG. 3, for example, the above-described press apparatus 202 further includes a camera 202c. The camera 202c is provided at a downstream position of the press device 202, and is provided so as to be able to image the absorbent body Ab in three-dimensional directions. The camera 202c takes, for example, an X-ray photograph of the absorber Ab.

Here, the camera 202c is an example of an image sensor that captures an image showing the state of the absorber Ab at a position downstream of the laminated portion 100. Therefore, not only the press device 202 but also the above-mentioned cutting device 203, leg hole cutting device 216, end cutting device 217, etc. may have an image sensor corresponding to the camera 202c. Of course, such an image sensor may be provided at any position on the absorbent conveyance path R2 as long as it is downstream from the laminated portion 100, but it is preferable that the image sensor is provided at least at a position after the absorbent body Ab has been subjected to pressure processing. preferable.

Furthermore, the laminated portion 100 has sensors in each of the pipes connected to the above-mentioned intake ports 104-A, 104-B, 104-C, 104-D, 104-E, and 104-F. As shown in FIG. 4, the stacked section 100 includes a pipe 106, a drive section 107, and an intake fan 108 behind the rotating drum 103.

The piping 106 is a duct that takes in air from each intake port 104-A, 104-B, 104-C, 104-D, 104-E, and 104-F. Note that, in order to make the drawing easier to read, FIG. Only shown. Each of the pipes 106-A, 106-C, and 106-D (see FIG. 5) connected to the intake ports 104-A, 104-C, and 104-D may be considered to be similar to the pipe 106-B.

The drive unit 107 rotates the rotating unit 103b of the rotating drum 103. The intake fan 108 is a fan in which each pipe 106 is collectively connected to form an intake air flow within each pipe 106 .

The laminated portion 100 includes a plurality of sensors that detect the state of each intake air flow. Such a plurality of sensors are arranged in the region P-Sr shown in FIG. The region P-Sr is, for example, a part of the straight portion of each pipe 106.

As shown in FIG. 5, three sensors are provided for each region P-Sr of each pipe 106, for example. The sensor is basically a pressure sensor. By measuring the pressure of the intake flow, the flow rate and flow rate can be calculated using Bernoulli's theorem, but a flow rate sensor or a flow rate sensor may be provided in addition to or together with the pressure sensor.

Each pipe 106 has a damper Dp in the region P-Sr. The sensors are arranged, for example, one on the upstream side and two on the downstream side of the intake flow across the damper Dp, and are provided so as to be able to measure at least the total pressure and static pressure in each pipe 106.

Next, the flow of intake air formed in the laminated portion 100 will be explained. As shown in FIG. 6, the rotating drum 103 has spaces A, B, C, D, and E formed in a hollow portion of the rotating portion 103b. Spaces A, B, C, D, and E are substantially closed spaces to which intake ports 104-A, 104-B, 104-C, 104-D, and 104-E are connected in order, and the above-mentioned recess 103a is connected to the spaces A, B, C, D, and E. It communicates with the outside air through. The spaces A, B, C, D, and E are so-called suction chambers, and correspond to an example of a suction section provided facing the inner circumferential surface of the rotating section 103b.

As shown in FIG. 7, the recess 103a is formed by a plate Pt attached along the outer peripheral surface of the rotating portion 103b. Here, as shown in FIG. 8, in the plate Pt, a portion corresponding to the bottom surface of the recess 103a is punched with a punching metal or the like, and holes with a smaller diameter than the holes on the bottom surface are arranged in the upper layer. A pore layer is formed.

There are a plurality of patterns on the bottom surface of the recess 103a formed by the plate Pt, depending on the specifications of each product, and the plate Pt can be replaced as appropriate depending on the product manufactured on the production line PL. Further, the plate Pt can be replaced as appropriate depending on clogging, aging deterioration, etc.

In addition, although FIG. 7 and FIG. 8 gave an example in which one plate Pt corresponds to one recess 103a, the aspect of the plate Pt is not limited, and a plurality of recesses 103a are formed in one plate Pt. may be done.

Returning to the explanation of FIG. 6. Spaces A, B, C, and D communicate with the outside air in the hood Fd via the bottom surface of the recess 103a. The space E communicates with the outside air outside the hood Fd via the bottom surface of the recess 103a.

Further, the stacking section 100 has a space F below the transfer position of the above-described absorbent body Ab on the transfer conveyor 105. Space F is a substantially closed space to which the intake port 104-F is connected. The space F communicates with the outside air at the upper surface of the absorber Ab on the transfer position side. Like the spaces A, B, C, D, and E, the space F is a suction chamber, so to speak, and corresponds to an example of a suction section provided facing the outer peripheral surface of the rotating section 103b.

In the laminated section 100 configured as above, when pulp fibers are fed into the hood Fd from the above-mentioned crusher 101 and SAP is spread into the hood Fd from the nozzle 102a of the spreader 102, the pulp fibers are separated by a multiphase flow. , and SAP are mixed.

On the other hand, when the above-mentioned intake fan is driven, an intake air flow is formed in each pipe 106, and the spaces A, B, C, D, E, and F each have a negative pressure. Therefore, in each of the spaces A, B, C, D, E, and F, the flow of intake air shown in FIG. 6 occurs.

In this state, in the example of FIG. 6, if the rotating part 103b rotates clockwise, the bottom surface of the recess 103a The pulp fibers in the hood Fd and the SAP are sucked and stacked.

Further, while the recess 103a passes through the position facing the space E, the stacked absorbent bodies Ab are held in the recess 103a so as not to fall. Then, when the recess 103a passes through the position facing the space F, the absorbent Ab is separated from the recess 103a by the flow of intake air generated in the space F, and is transferred onto the transfer conveyor 105.

Furthermore, the aforementioned camera 202c captures an image of the absorbent body Ab that is pressurized from above and below in the press device 202. The camera 202c captures an X-ray image as shown in FIG. 9, for example. By analyzing the image captured by the camera 202c, it is possible to detect, for example, the distribution state of pulp fibers and SAP.

Further, in the press device 202, when the absorbent body Ab passes between the press rolls 202a and 202b, at least one of the press rolls 202a and 202b vibrates depending on the smoothness of the absorbent body Ab. At this time, the press device 202 can measure the vibration of the rotating shaft of the press roll 202a and/or the press roll 202b during such vibration as a displacement amount (distance) a from the reference plane using a displacement sensor (not shown). can. By analyzing this amount of displacement a, it becomes possible to detect, for example, the lamination state of pulp fibers and SAP. Note that the press device 202 can also detect the laminated state by measuring the vibration of at least one of the press roll 202a and the press roll 202b when the absorber Ab passes by using a vibration sensor (not shown). good.

[2-2. Manufacturing system configuration example]
Next, FIG. 10 is a block diagram showing a configuration example of the manufacturing system 1 according to the embodiment. In addition to FIG. 10, block diagrams are also shown in FIG. 11 shown later, but these block diagrams only represent the components necessary to explain the features of this embodiment, and do not represent general components. Description is omitted.

In other words, each component illustrated in these block diagrams is functionally conceptual, and does not necessarily need to be physically configured as illustrated. For example, the specific form of distributing/integrating each block is not limited to what is shown in the diagram, and all or part of the blocks can be functionally or physically distributed/integrated in arbitrary units depending on various loads and usage conditions. It is possible to configure them in an integrated manner.

Furthermore, in the explanations using these block diagrams, the explanations of components that have already been explained may be simplified or omitted.

As shown in FIG. 10, the manufacturing system 1 according to the embodiment includes a monitoring device 10, a manufacturing management device 20, a manufacturing line PL, and a user terminal 500.

The monitoring device 10, the manufacturing management device 20, and the manufacturing line PL are communicably connected to each other via a network N-1, which is a wired or wireless communication line. The network N-1 is, for example, an intranet made up of a LAN (Local Area Network) or the like.

The monitoring device 10 and the user terminal 500 are communicably connected to each other via a network N-2, which is a wired or wireless communication line. The network N-2 is, for example, a communication network such as a LAN, a WAN (Wide Area Network), a telephone network (mobile phone network, fixed telephone network, etc.), a local IP (Internet Protocol) network, or the Internet. Note that hereinafter, when there is no particular need to distinguish between networks N-1 and N-2, they will simply be referred to as "network N."

The monitoring device 10 and at least a portion of the manufacturing line PL constitute a manufacturing device 50 according to the embodiment. At least a portion of the manufacturing line PL referred to herein includes the laminated section 100, various sensors Sr included in the laminated section 100, and other various sensors Sr included in the manufacturing line PL.

[2-3. About the monitoring device]
The monitoring device 10 acquires first information, which is information related to the manufacture of the diaper D, from at least various sensors Sr provided in the lamination section 100, and obtains second information, which is information related to the product of the diaper D in the production line PL. This is the device to acquire. Further, the monitoring device 10 stores the acquired first information and second information in association with each other, determines whether or not there is an abnormality in at least the laminated portion 100 based on the first information and the second information, and determines This is a device that outputs the results.

The monitoring device 10 has a state analysis model DB (Database) 13b. The monitoring device 10 uses the state analysis model DB 13b to analyze the state of the laminated portion 100 based on the first information and the second information, and determines whether or not there is an abnormality in at least the laminated portion 100.

A specific example of the analysis method using the state analysis model DB 13b will be described later with reference to FIGS. 16 to 18.

Furthermore, the monitoring device 10 outputs the determination result to an HMI (Human Machine Interface) section 12 (see FIG. 11) that the monitoring device 10 has. The HMI section 12 is a human interface component, and includes output components such as a display and speakers, and input components such as a keyboard and a touch panel.

Furthermore, the monitoring device 10 generates control signals for controlling various mechanisms in the production line PL as a result of the determination, and outputs them to the production line PL via the network N-1. Furthermore, the monitoring device 10 outputs the determination result to the user terminal 500 via the network N-2.

[2-4. About manufacturing control equipment]
The manufacturing management device 20 is a device that manages information regarding products of diapers D on the manufacturing line PL. The manufacturing management device 20 is used by a manager or the like who manages the manufacturing line PL. The manufacturing management device 20 has a manufacturing management DB 21. The manufacturing management DB 21 stores various information regarding the diaper D product.

The information regarding the diaper D product includes, for example, a schedule for manufacturing the diaper D, a product number that uniquely identifies each manufactured diaper D, and the like. Further, the information regarding the diaper D product includes, for example, information regarding the type and composition of the material used for each product. The material includes at least one of pulp, synthetic fiber, and SAP.

[2-5. About the production line]
The manufacturing line PL includes a lamination section 100 and a plurality of processing sections 300 other than the lamination section 100. The plurality of processing units 300 include the above-described material coils 201, 205, 211, press device 202, cutting device 203, adhesive coating device 204, 209, 210, 215, slip cutting device 206, 212, temporary press roll 207, 213. , the main press devices 208 and 214, the leg hole cutting device 216, the end cutting device 217, and the conveying device forming each of the conveying routes R1 to R7.

The laminated section 100 includes various sensors Sr. The various sensors Sr included in the laminated portion 100 include the sensor 102b of the above-mentioned spreader 102, a plurality of sensors provided in each pipe 106, and the like. Furthermore, each of the processing units 300 has various sensors Sr. The various sensors Sr included in the processing unit 300 include the displacement sensor included in the press device 202, the vibration sensor, the camera 202c, and the like.

[2-6. About user terminal]
The user terminal 500 is an information processing device used by a manager, a worker, etc. of the production line PL. The user terminal 500 may be, for example, an information processing device such as a mobile phone including a smartphone, a tablet terminal, a desktop PC (Personal Computer), a notebook PC, or a PDA (Personal Digital Assistant). Further, the user terminal 500 may be a wearable device that is a glasses-shaped or watch-shaped information processing device.

[2-7. Configuration example of monitoring device]
Next, FIG. 11 is a block diagram showing a configuration example of the monitoring device 10 according to the embodiment. As shown in FIG. 11, the monitoring device 10 includes a communication section 11, an HMI section 12, a storage section 13, and a control section 14.

Further, the monitoring device 10 is connected to the various sensors Sr shown in FIG. 10, the manufacturing control device 20, the network N-2, and various mechanisms Mc of the manufacturing line PL via the communication unit 11. The various mechanisms Mc are, for example, the damper Dp of the piping 106 described above.

The communication unit 11 is realized by, for example, a network adapter. The communication unit 11 executes communication processing between the various sensors Sr, the network N-2, the various mechanisms Mc, and the control unit 14. Since the HMI section 12 has already been explained, the explanation here will be omitted.

The storage unit 13 is realized by, for example, a semiconductor memory element such as a RAM (Random Access Memory) or a flash memory, or a storage device such as a hard disk or an optical disk. The storage unit 13 may be realized by, for example, NAS (Network Attached Storage). In the example of FIG. 11, the storage unit 13 stores an acquired information DB 13a and a state analysis model DB 13b.

The acquired information DB 13a stores manufacturing information (corresponding to an example of "first information") acquired by a manufacturing information acquiring section 14a and a product information acquiring section 14b, which will be described later, and product information (an example of "second information"). This is a database that stores information (equivalent to ).

The state analysis model DB 13b is a database in which various state analysis models used by the analysis section 14c, which will be described later, are stored.

Here, various types of information stored in the acquired information DB 13a will be explained with reference to FIGS. 12 to 15. FIG. 12 is a diagram showing an example of sensor information stored in the acquired information DB 13a. Moreover, FIG. 13 is a diagram showing an example of plate information stored in the acquired information DB 13a. Moreover, FIG. 14 is a diagram showing an example of product information stored in the acquired information DB 13a. Further, FIG. 15 is an explanatory diagram of an example of linking manufacturing information and product information.

As shown in FIG. 12, the acquired information DB 13a stores, for example, "sensor information". "Sensor information" includes a "sensor ID" item, an "installation location" item, a "data type" item, a "reference value" item, and a "sensor data" item. The "sensor information" corresponds to an example of manufacturing information regarding the manufacturing of the diaper D. The data stored in each item of "sensor information" is acquired from various sensors Sr and the manufacturing management DB 21, for example.

The "sensor ID" item stores identification information that uniquely identifies each sensor Sr. The "installation location" item stores the installation locations of each of the various sensors Sr. The "data type" item stores the type of sensor data measured by each of the various sensors Sr. The "reference value" item stores reference values of sensor data for each of the various sensors Sr. The "sensor data" item stores sensor data for the most recent predetermined period measured by each of the various sensors Sr.

The example in FIG. 12 shows that the sensor with the sensor ID "S-01" is the sensor 102b provided in the spreader 102, and that the sensor 102b is a flow rate sensor that measures the flow rate of the SAP.

In addition, in the example of FIG. 12, the sensors with sensor IDs "A-01" to "A-03" are the sensors installed in the A pipe, and the sensors with sensor IDs "A-01" and "A-02" indicates a pressure sensor. Furthermore, the sensor with sensor ID "A-03" is shown to be a flow rate sensor. Note that "Pipe A" represents the pipe 106-A connected to the intake port 104-A.

In addition, in the example of FIG. 12, the sensors with sensor IDs "B-01" to "B-03" are the sensors installed in the B pipe, and the sensors with sensor IDs "B-01" and "B-02" indicates a pressure sensor. Further, the sensor with sensor ID “B-03” is shown to be a flow rate sensor. Note that "Pipe B" represents the pipe 106-B connected to the intake port 104-B.

Further, the example in FIG. 12 shows that the sensor with sensor ID “X-01” is a displacement sensor provided in the press device 202. Further, the example in FIG. 12 shows that the sensor with the sensor ID “Y-01” is the camera 202c provided at the downstream position of the press device 202.

Furthermore, the various sensors Sr may be sensors that acquire sensor data other than the data types mentioned above. For example, the example in FIG. 12 shows that the sensor with the sensor ID "T-01" is a temperature sensor placed in the stack section where the stack section 100 is provided. Further, the example in FIG. 12 shows that the sensor with the sensor ID "H-01" is a humidity sensor placed in the laminated section where the laminated section 100 is provided.

Note that the temperature of the laminated portion 100 is considered to affect the specific gravity and bulk of the absorber Ab, the flow rate of intake air, the way the sprayed matter falls, the hydrogen bonds of the absorber Ab, and the like. Similarly, the humidity of the laminated section 100 is thought to affect the ease with which static electricity is generated, changes in weight balance due to adhesion of the hood Fd to the wall surface, ease of transfer, ease of clogging, etc. .

Further, as shown in FIG. 13, the acquired information DB 13a stores, for example, "plate information" which is information regarding the above-mentioned plate Pt. "Plate information" corresponds to an example of manufacturing information regarding the manufacturing of diaper D. The data stored in each item of "plate information" is acquired from the manufacturing management DB 21, for example.

"Plate information" includes the "recess ID" item, the "plate ID" item, the "logical number" item, the "front and back plates" item, the "start date of use" item, the "last maintenance date" item, ``Scheduled replacement date'' item.

The “recess ID” item stores identification information that uniquely identifies the recess 103a of the rotating drum 103. The "Plate ID" item stores identification information that uniquely identifies the plate Pt.

The "logical number" item stores a logical number that is cyclically assigned to each plate Pt on the production line PL. The “front and rear plates” item stores plate IDs indicating the front and rear attachment directions of one plate Pt on the outer peripheral surface of the rotating drum 103.

The "use start date" item stores the use start date of the corresponding plate Pt. The "last maintenance date" field stores the last maintenance date of the relevant plate Pt, and the "scheduled replacement date" field stores the scheduled replacement date of the relevant plate Pt.

Further, as shown in FIG. 14, the acquired information DB 13a stores, for example, "product information" that is information regarding the above-mentioned products. "Product information" includes the "product number" item, "manufacturing date and time" item, "daily SEQ number" item, "corresponding logical number" item, "pulp material type" item, and "SAP moisture content" including items. "Product information" corresponds to an example of product information regarding the diaper D product. The data stored in each item of "product information" is acquired from the manufacturing management DB 21, for example.

Identification information that uniquely identifies the diaper D is stored in the "product number" item. The "manufacturing date and time" item stores the manufacturing date and time when each diaper D was manufactured. The "daily SEQ number" is, for example, a number included as part of the manufacturing number, and stores the sequential number assigned to each diaper D each time the manufacturing line PL is operated daily.

The "corresponding logical number" item stores a logical number (see FIG. 13) that corresponds to the first daily product number, for example, when the daily production line PL starts operating.

As shown in FIG. 15, the logical number of plates Pt is assigned cyclically to each plate Pt. Note that the example in FIG. 15 shows a case where the rotating drum 103 is provided with eight recesses 103a.

On the other hand, daily SEQ numbers are assigned sequentially over time. Here, as shown in FIG. 14, for example, by linking the logical number corresponding to the first daily product number, when a defective diaper D occurs, the logical number corresponding to the diaper D is It is possible to determine the number. Furthermore, this makes it possible to specify the plate Pt that corresponds to the logical number.

Note that although "daily" is used here, this is just an example based on the premise that the timing at which the production line PL starts operation is daily, and the timing at which SEQ number counting starts is limited. It's not something you do.

Moreover, what is shown in FIG. 15 is merely an example of linking manufacturing information and product information, and other methods can of course be used. As another example, if the conveyance speed of the absorbent body conveyance path R2 is unchanged, the time when a defect is discovered in the absorbent body Ab, the distance from the absorbent body Ab to the laminated section 100, and the distance included in this distance are as follows. It is possible to determine the corresponding plate Pt from the number of absorbers Ab included.

Returning to the explanation of FIG. 14. Further, in the "pulp material type" item of "product information", data indicating the pulp material type used to manufacture the diaper D having the corresponding product number (here, "b type") is stored. Note that the ease of clogging is thought to vary depending on the pulp material type. Further, in the "SAP water content" item, data indicating the water content of SAP used to manufacture the diaper D of the corresponding product number is stored.

Although not shown in FIG. 14, the "product information" includes information regarding not only the finished diaper D but also the semi-finished product. Therefore, for example, data of an image (see FIG. 12), such as a binarized image obtained by binarizing an X-ray image of a semi-finished product shown in FIG. 9, may be included in the product information. Further, the image data may be an image other than a binarized image or a brightness distribution image.

The analysis unit 14c, which will be described later, can determine at least the presence or absence of an abnormality in the laminated portion 100 by analyzing the state of the laminated portion 100 based on the various information shown in FIGS. 12 to 14.

Returning to the explanation of FIG. 11. The control unit 14 is a controller, and various programs stored in the storage unit 13 use a RAM (Random Access Memory) as a work area by, for example, a CPU (Central Processing Unit) or an MPU (Micro Processing Unit). This is achieved by executing as . Further, the control unit 14 can be realized by, for example, an integrated circuit such as an ASIC (Application Specific Integrated Circuit) or an FPGA (Field Programmable Gate Array).

The control unit 14 includes a manufacturing information acquisition unit 14a, a product information acquisition unit 14b, an analysis unit 14c, a determination unit 14d, and an output unit 14e, and implements or functions the information processing functions and operations described below. Execute.

The manufacturing information acquisition unit 14a acquires manufacturing information regarding the manufacturing of the diaper D from various sensors Sr and the manufacturing control device 20 via the communication unit 11. Further, the manufacturing information acquisition unit 14a stores the acquired manufacturing information in the acquired information DB 13a.

The product information acquisition unit 14b acquires product information regarding the diaper D from the various sensors Sr and the manufacturing control device 20 via the communication unit 11. Further, the product information acquisition unit 14b stores the acquired product information in the acquired information DB 13a.

The analysis section 14c analyzes the state of the laminated section 100 based on the manufacturing information and product information stored in the acquired information DB 13a, using various state analysis models stored in the state analysis model DB 13b.

Here, a specific example of the analysis process using the state analysis model executed by the analysis unit 14c will be described with reference to FIGS. 16 to 18. FIG. 16 is a diagram (part 1) showing a specific example of analysis processing. Further, FIG. 17 is a diagram (part 2) showing a specific example of the analysis process. Further, FIG. 18 is a diagram (part 3) showing a specific example of the analysis process.

The analysis unit 14c most simply uses a state analysis model that analyzes the state of the laminated portion 100 using a predetermined abnormality determination threshold. In such a case, the analysis unit 14c analyzes that there is an abnormality in at least the laminated portion 100 when the sensor data exceeds the abnormality determination threshold or is below the abnormality determination threshold, depending on the type of the various sensors Sr.

Further, as shown in FIG. 16, the analysis unit 14c analyzes the state of each pipe 106 using, for example, a state analysis model provided for each pipe A, pipe B, etc. of the laminated portion 100. Then, the analysis section 14c generates an analysis result for the entire stacked section 100 based on the analysis result for each pipe 106.

In such a case, the analysis unit 14c analyzes that there is an abnormality in the entire stacked part 100, for example, when an abnormality is recognized in at least one of the analysis results of each pipe 106. Further, the analysis unit 14c analyzes that there is an abnormality in the entire stacked part 100, for example, when an abnormality is recognized in the majority of the analysis results of each pipe 106. Further, the analysis unit 14c analyzes that there is an abnormality in the entire stacked part 100, for example, when abnormality is recognized in all of the analysis results of each pipe 106.

Note that although the example in FIG. 16 shows an example based on sensor data provided at least in each pipe 106 of the laminated section 100, it is also possible to use a state analysis model corresponding to each of the various sensors Sr in the entire production line PL. You can also use it as

Further, as shown in FIG. 17, the analysis unit 14c analyzes the state of the laminated portion 100, for example, by multivariate analysis based on sensor data from various sensors Sr. In such a case, the analysis unit 14c calculates an evaluation score indicating the state of the laminated portion 100 using, for example, a multivariate analysis model included as a state analysis model in the state analysis model DB 13b.

The multivariate analysis model uses the sensor data of various sensors Sr, the above-mentioned manufacturing information, and each element of product information as explanatory variables to solve a statistical formula for abnormality prediction. Calculate the status evaluation score.

At this time, appropriate weights may be assigned to the explanatory variables depending on the situation indicated by each element of manufacturing information and product information. For example, the explanatory variable indicating the abnormality of the plate Pt may be weighted according to the number of days until the scheduled replacement date of the plate Pt, so that the longer the number of days is, the heavier the weight is, and the shorter the number of days is, the lighter the weight is.

Furthermore, as shown in FIG. 18, the analysis unit 14c analyzes the state of the laminated portion 100 using, for example, a normal state model included as a state analysis model in the state analysis model DB 13b. The normal state model is a learning model generated by machine learning the correlation of sensor data of various sensors Sr during normal operation of the production line PL.

This normal state model calculates the degree of deviation from the normal state by inputting, for example, real-time sensor data from various sensors Sr. As the machine learning algorithm, for example, a deep learning algorithm is used.

Note that when using a machine learning algorithm, the normal state model may be one that calculates the degree of deviation from the normal distribution state when an image showing the above-mentioned distribution state is inputted by the camera 202c, for example. . Further, when the normal state model shown in FIG. 18 is used, the degree of deviation from the normal state is determined, so it is also useful for detecting a sign of an abnormality that does not lead to an abnormality.

Returning to the explanation of FIG. 11. The determination unit 14d determines whether or not there is an abnormality in at least the laminated portion 100 based on the analysis result by the analysis unit 14c. The output unit 14e outputs the determination result by the determination unit 14d.

The output unit 14e outputs the determination result to the HMI unit 12. Further, the output unit 14e outputs the determination result to the user terminal 500 via the communication unit 11. At this time, the output unit 14e converts the determination result into, for example, instruction content for a worker or the like, and outputs it to the HMI unit 12 and/or the user terminal 500. The contents of the instructions include the contents of operations performed by the worker on various mechanisms Mc.

If the period until the next scheduled maintenance date is short, the output unit 14e outputs instruction content for boost control to extend the life in the short term until then. Specifically, if the analysis result by the analysis unit 14c indicates that the plate Pt is clogged, for example, the output unit 14e outputs an instruction to the operator to increase the air volume of the intake fan 108. Further, in the same case, the output unit 14e outputs an instruction to adjust the opening degree of the damper Dp. Further, in the same case, the output unit 14e outputs an instruction to clean the corresponding plate Pt.

Further, when the various mechanisms Mc can be automatically controlled, the output unit 14e generates a control signal for controlling the various mechanisms Mc as a determination result and outputs it to the various mechanisms Mc.

[3. Processing procedure]
Next, with reference to FIG. 19, a processing procedure executed by the monitoring device 10 according to the embodiment will be described. FIG. 19 is a flowchart showing the processing procedure executed by the monitoring device 10 according to the embodiment.

First, the manufacturing information acquisition unit 14a acquires manufacturing information regarding diaper manufacturing from at least a sensor provided in the lamination unit 100 (step S101).

Then, the product information acquisition unit 14b acquires product information regarding the diaper D product on the production line PL (step S102).

Then, the storage unit 13 stores manufacturing information and product information in association with each other (step S103).

Further, the determination unit 14d determines whether or not there is an abnormality at least in the laminated portion 100 based on the stored manufacturing information and product information (step S104). Then, the output unit 14e outputs the determination result by the determination unit 14d (step S105), and the monitoring device 10 repeats the processing from step S101.

Note that, so far, pressure sensors, flow rate sensors, displacement sensors, cameras, temperature sensors, and humidity sensors have been cited as examples of various sensors Sr, but the types of sensors are not limited. Therefore, any sensor may be used as long as it is provided in the absorbent article production line PL, and for example, it may be a tension sensor that measures the tension of a continuous web.

[4. others〕
Among the above-described processes, all or part of the processes described as being performed automatically may be performed manually. Further, all or part of the processing described as being performed manually may be performed automatically by a known method. In addition, information including the processing procedures, specific names, and various data and parameters shown in the above documents and drawings may be changed arbitrarily, unless otherwise specified. For example, the various information shown in each figure is not limited to the illustrated information.

Furthermore, each component of each device shown in the drawings is functionally conceptual, and does not necessarily have to be physically configured as shown in the drawings. That is, the specific form of distributing and integrating each device is not limited to what is illustrated. In addition, all or part of each component may be functionally or physically distributed and integrated in arbitrary units depending on various loads and usage conditions. Furthermore, the above-described processes may be executed in combination as appropriate to the extent that they do not contradict each other.

[5. Hardware configuration]
Further, the monitoring device 10 according to the embodiment described above is realized by, for example, a computer 1000 having a configuration as shown in FIG. 20. FIG. 20 is a diagram showing an example of the hardware configuration. The computer 1000 is connected to an output device 1010 and an input device 1020, and includes an arithmetic device 1030, a cache 1040 as a primary storage device, a memory 1050 as a secondary storage device, an output IF (Interface) 1060, an input IF 1070, and a network IF 1080. 1090.

The arithmetic unit 1030 operates based on programs stored in the cache 1040 and memory 1050, programs read from the input device 1020, and performs various processes. The cache 1040 is a cache, such as a RAM, that temporarily stores data used by the arithmetic unit 1030 for various calculations. Further, the memory 1050 is a storage device in which data used by the arithmetic unit 1030 for various calculations and various databases are registered, and is realized by a ROM (Read Only Memory), an HDD (Hard Disk Drive), a flash memory, etc. memory.

The output IF 1060 is an interface for transmitting information to be output to an output device 1010 that outputs various information such as a monitor or a printer, and is, for example, a USB (Universal Serial Bus), a DVI (Digital Visual Interface), It may be realized by a connector of a standard such as HDMI (registered trademark) (High Definition Multimedia Interface). On the other hand, the input IF 1070 is an interface for receiving information from various input devices 1020 such as a mouse, a keyboard, and a scanner, and is realized by, for example, a USB or the like.

For example, the input device 1020 may be an optical recording medium such as a CD (Compact Disc), a DVD (Digital Versatile Disc), or a PD (Phase change rewritable disk), a magneto-optical recording medium such as an MO (Magneto-Optical disk), a tape medium, It may be realized by a device that reads information from a magnetic recording medium, a semiconductor memory, or the like. Further, the input device 1020 may be realized by an external storage medium such as a USB memory.

The network IF 1080 has a function of receiving data from other devices via the network N and sending it to the computing device 1030, and also transmitting data generated by the computing device 1030 to the other devices via the network N.

Here, the arithmetic device 1030 controls the output device 1010 and the input device 1020 via the output IF 1060 and the input IF 1070. For example, the arithmetic device 1030 loads a program from the input device 1020 or the memory 1050 onto the cache 1040, and executes the loaded program. For example, when the computer 1000 functions as the monitoring device 10, the arithmetic unit 1030 of the computer 1000 executes the program loaded on the cache 1040, thereby controlling the manufacturing information acquisition unit 14a, the product information acquisition unit 14b, and the analysis unit 14c. , the determination unit 14d, and the output unit 14e.

The embodiments of the present application have been described above in detail based on the drawings. However, these are merely examples, and the embodiments of the present application may be implemented in other forms with various modifications and improvements based on the knowledge of those skilled in the art, including the embodiments described in the disclosure section of the invention. is possible. Further, the above-mentioned "section, module, unit" can be read as "means", "circuit", etc.

1 Manufacturing System 10 Monitoring Device 13 Storage Unit 14 Control Unit 14a Manufacturing Information Acquisition Unit 14b Product Information Acquisition Unit 14c Analysis Unit 14d Judgment Unit 14e Output Unit 50 Manufacturing Equipment 100 Lamination Unit 103 Rotating Drum 103a Recess 103b Rotating Unit 106 Piping 108 Intake Fan D Diaper PL Production line Pt King rate Sr Various sensors

Claims (13)

In absorbent article manufacturing equipment,
a laminating unit that laminates the absorbent body in the absorbent article from pulverized and/or defibrated materials;
a first acquisition unit that acquires first information that is information regarding manufacturing of the absorbent article from a sensor provided at least in the laminated part;
a second acquisition unit that acquires second information that is information regarding the product of the absorbent article in the manufacturing line of the absorbent article;
a storage unit that stores the first information and the second information in association with each other;
a determination unit that determines whether or not there is an abnormality in at least the laminated portion based on the first information and the second information;
An apparatus for manufacturing an absorbent article, comprising: an output section that outputs a determination result by the determination section. The laminated portion is
A rotating drum having a rotating part provided in an annular shape and rotatable around the central axis of the annular ring, and in which a plurality of recesses or continuous recesses are formed along the outer peripheral surface of the rotating part;
a suction section provided opposite to the inner circumferential surface and the outer circumferential surface of the rotating section;
The material is suctioned into the recess by an intake air flow through a pipe connected to the suction section behind the rotating drum to stack the absorbent bodies, and the stacked absorbent bodies are removed from the recess. Equipped with an intake fan that allows
The absorbent article manufacturing apparatus according to claim 1, wherein a plurality of the sensors are provided in the piping. The piping is
A plurality of connections are made to the suction part,
The sensor is
The apparatus for manufacturing an absorbent article according to claim 2, wherein a plurality of pipes are provided in each straight line portion. The first information is
The absorbent article manufacturing apparatus according to claim 2 or 3, further comprising information regarding the pressure and/or flow rate of the intake air flowing through the piping. The sensor is
The absorbent article manufacturing apparatus according to claim 4, wherein the absorbent article manufacturing apparatus is at least one of a pressure sensor, a flow rate sensor, and a flow rate sensor. The recess is
formed by replaceably provided plates;
The absorbent article manufacturing apparatus according to claim 2, wherein the first information includes information regarding the plate. Information regarding the plate is
The absorbent article manufacturing apparatus according to claim 6, comprising at least one of information regarding identification of the plate, information regarding previous maintenance, and information regarding next replacement. The second information is
The apparatus for manufacturing an absorbent article according to claim 1, 2 or 3, characterized in that the apparatus includes information regarding a finished product and/or a semi-finished product of the product. further comprising an image sensor provided at a position downstream of the laminated section in the manufacturing line,
The second information is
The absorbent article manufacturing apparatus according to claim 8, further comprising information regarding an image showing the state of the absorbent body captured by the image sensor. The material is
Containing at least one of pulp, synthetic fiber, and polymeric absorbent material,
The absorbent article manufacturing apparatus according to claim 1, wherein the second information includes information regarding the material. further comprising a temperature sensor and/or a humidity sensor;
The first information is
The absorbent article manufacturing apparatus according to claim 1, further comprising information regarding the temperature measured by the temperature sensor and/or information regarding the humidity measured by the humidity sensor. A manufacturing method carried out by a manufacturing device having a lamination unit that laminates an absorbent body in an absorbent article from pulverized and/or defibrated materials,
a first acquisition step of acquiring first information that is information regarding manufacturing of the absorbent article from a sensor provided at least in the laminated part;
a second acquisition step of acquiring second information that is information regarding the product of the absorbent article in the absorbent article manufacturing line;
a storage step of storing the first information and the second information in association with each other;
a determination step of determining the presence or absence of an abnormality in at least the laminated portion based on the first information and the second information;
A method for manufacturing an absorbent article, comprising: an output step of outputting the determination result in the determination step. A first acquisition step of acquiring at least first information, which is information regarding the manufacture of the absorbent article, from a sensor provided in a lamination section that laminates absorbers in the absorbent article from pulverized and/or defibrated materials; and,
a second acquisition procedure for acquiring second information that is information regarding the product of the absorbent article in the absorbent article manufacturing line;
a storage procedure for storing the first information and the second information in association with each other;
a determination procedure for determining the presence or absence of an abnormality in at least the laminated portion based on the first information and the second information;
A program that causes a computer to execute the following: an output procedure for outputting a determination result based on the determination procedure.

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