MXPA01006597A - Making absorbent articles using vision imaging system - Google Patents

Abstract

Apparatus and method using vision imaging for combined short- and long-term monitoring and control of a manufacturing operation which produces absorbent articles. The system collects discrete real-time visual imagine provides an ongoing display of such images, and upon occurrence of a triggering event, continues the display of the images while sending information representing a limited number of real-time images to a memory storage system which receives and permanently stores the information. The data is received in a temporary memory device, and written from there to a second permanent memory device. While the images are being sent to the memory storage system, process control logic analyzes the images in real time, and sends results signals to manufacturing operation. A second set of such images can be sent to the memory system in response to the second, triggering event. After sending any set of real-time images to memory storage, 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 process steps, along the manufacturing line.

Description

MANUFACTURE OF ABSORBENT ITEMS USING A VISUAL IMAGE SYSTEM BACKGROUND OF THE INVENTION The present invention relates to apparatus and methods for monitoring and evaluating manufacturing operations that produce a continuous flow of discrete absorbent articles effective to absorb body fluids. These products are normally manufactured as a sequence of work pieces in a continuous fabric. The absorbent articles generally consist of an absorbent core confined between a moisture impermeable diverter of, for example, polyethylene and an additional liner for the previously wet body, for example, nonwoven fibrous material. The absorbent articles are made by advancing one of the fabrics along a longitudinally extending path, applying the absorbent core to one of the first fabrics, and then applying it to the second fabric. Other elements such as elastics, leg cuffs, restraining wings, hip bands and the like, are added in the manner desired for the particular product being manufactured, either before or after applying the second fabric. These elements can be oriented longitudinally along the path, or transversely to the path, or they can have a neutral orientation.

When certain events occur, the products manufactured by such manufacturing operations can be moved out of a tolerance margin of predetermined specifications required, where the correction action must be taken in the manufacturing operation: or the product may fall outside said operations. specifications and could be discarded from the product flow.

A variety of possible events in the manufacturing operation can result in the production of absorbent articles that fall outside the specification range. For example, elastic materials can be stretched more or less than desired. The elements may be misaligned in relation to the correct record in the manufacturing operation. The synchronization between the steps of the process and the forward speed of an element may be slightly out of tolerance. If such non-catastrophic changes can be detected in the process conditions fast enough, process corrections can usually be made, and target variations reduced, without having to interrupt the manufacturing operation and without having to discard and therefore , waste the product.

In any case, inherently, certain cases result in the manufacture of the product out of tolerance by means of which no amount of process control can prevent product disposal. As an example of these cases are the splices in the continuous base fabric.

Where the product is outside the specification range, and should be discarded, you want to discard all the defective product, but only that product that is actually defective. If very little product is disposed of, or if the wrong product is discarded, then the defective product is being improperly released into the flow of commerce. If the product that actually meets the specifications of the product is discarded, then the good product is being wasted.

Absorbent articles that absorb body fluid are typically manufactured at speeds of approximately 50 to 1200 items per minute in a given production line. According to this, it is impossible for an operator to manually check each and every article produced. If the operator reacts prudently, and discards the product whenever he or she has a suspicion, but not solid evidence, that something of the product may not meet the specifications, then, in reality a significant amount of the good product will have been discarded. . In any case, if the operator takes action only when a defect has been confirmed using the visual check, the defective product may have already been released into the flow of the trade.

One way for the operator to review the product so that it meets the specification margin, is for the operator to collect and periodically review, offline, physical samples of the product that is produced. Randomly conducting such revisions is unlikely to detect temporary conditions outside of the specifications. Where such samples are taken in response to a suspicion to conditions outside the specifications, given the high rate of speed at which these items are manufactured, by the time the operator finishes its review, the suspected offensive condition may have existed enough time in which the questionable product has already been sent and discarded without the operator having any solid basis on which to make the decision to weave or discard. In addition, the controls of the automated manufacturing process may have corrected themselves the defect condition before the operator has finished the visual inspection and acts on the results of the visual inspection.

While offline review is the main determinant of quality, and defines the quality and final disposal of the product, online review and offline review of data gathered online, usually associated with certain manufacturing events, can provide valuable disclosures within the operational characteristics of the manufacturing process, and final parameters 5 of product quality.

Recent advances in product review include the use of one or more visual imaging systems that have a camera positioned along the manufacturing path.

In this way, a camera of the visual image system can be placed in a fixed place, to gather visual images of the product in that place. The visual imaging system continuously gathers images of the work pieces of the product while the precursors of the product pass the point in the manufacturing process that is being monitored. Thus, the assembled images are transmitted to a visual display device such as a video monitor at the operator station, where the operator can visually monitor certain visual parameters of the product in the respective place along the manufacturing trajectory.

Such visual imaging systems usually operate continuously during manufacturing operations, so that the operator can continuously, or at any time, monitor the condition of the product that is It is manufactured at a given place in the production line. Either way, conventional visual image systems that work continuously, provide no mechanism for the operator to archive any of the images being reviewed.

Some current visual image systems can be used to instantly capture the entire digital representation of a visual image, and to capture and transfer measurement information that represents limited portions of each of the images to be evaluated, but have very limited capacity to store or transfer complete visual images in relation to that information. The memory storage capacity of said visual image systems provides a limited capacity to temporarily or permanently store the collected visual images. The images and information collected can be transferred to permanent storage within the visual image system, but the image system has a very limited capacity to permanently store the images, and that permanent storage will compromise the ability to continue gathering information, while transferring simultaneously the information gathered to the permanent storage at the speeds of production contemplated here, for example and without limitation, of at least 200 revisions per minute.

The ability to gather information simultaneously, and transfer information to permanent storage, is a function of both the complexity of reviewing images that are captured and analyzed, and the frequency with which images are captured. At normal manufacturing speeds to manufacture absorbent articles such as diapers and incontinence products, ie, at least 300 to 400 units per minute, current visual imaging systems are unable to sustain the necessary rates of continuous simultaneous capture and transfer of available images to capture at the speed of one image per production unit.

The elimination or transfer of information, and re-start the collection process in the existing visual image system, usually includes the intervention of the operator, but can be done through the pre-programmed computer control. While the limited amounts of data can be gathered and filed from a high-speed operation as illustrated in the drawings, the amount of information that can be gathered in relation to a given event is very limited.

Normally, the current freeze image systems will freeze on the first detected defective image. Re-starting the collection process can be preprogrammed and in this way, controlled by computer, or it can be manual. According to this, to the extent to which the continuous manufacturing process is producing information that could be useful for the operation and / or analysis of the process, current image systems have very limited capacity to gather, archive, and then reconstruct the images visuals of said information. While a limited set of measurement data of said images can be archived, and retrieved, such information is insufficient to reconstruct the desired visual images.

Other visual imaging systems such as the KODAK® EKTAPRO® Model 1012 Motion Analyzer can be used to capture complete visual images, but not to automatically generate measurement data. This visual image system can collect and display real-time video images, and can store up to 1637 of the most recent frames of video images in memory. The images can be synchronized with the manufacturing operation so that each frame / image shows and represents each consecutive work piece. Also, this portable system is inconvenient for continuous work operation, and can only retain in storage the last 1637 frames. Stored images can be transferred to a limited number of video recorder models, but camera recording can not be carried out simultaneously with the transfer to the video recorder. In this way, where a particular set of images of interest is found, the images are lost as soon as additional images greater than 1637 frames are taken, or the recording of the camera must stop to transfer the images to the VCR. In any case, as indicated above, the KODAK EKTAPRO system by itself does not generate measurement data related to said images without manual intervention.

According to this, current systems are unable to automatically and simultaneously capture and transfer both the complete digital image and the selected measurement data desired for permanent storage. In this way, the user is distressed between the need to retain certain information that may be valuable for further analysis and the need to continue monitoring the real-time images of the items that are currently occurring in the manufacturing operation.

In this way, it is desired to provide a quality control process and / or an apparatus capable of monitoring the real-time condition of the articles that are manufactured, and which is simultaneously capable of selectively archiving certain sets of visual image data in a memory storage device.

Accordingly, it is desired to send visual image information to the memory storage only if one or more activation cases related to the manufacturing operation occur and while the image recording per camera is continuous.

It is desired that, upon occurrence of the activation event, the apparatus and / or process automatically send preselected images to the memory storage as visual image information.

It is desired that, during the time in which the visual image information is sent to the storage, the exposure of the visual image continues uninterrupted and unchanged, selecting and displaying images without being affected by the fact that the visual images are being transferred. to the storage of data.

In addition, it is desired to provide the quality control process and / or apparatus wherein the visual exposure continues without decreasing before, during and after, sending the visual images to storage.

It is also desired to provide the quality control process and / or apparatus that first sends the visual image information for storage, to a high speed temporary memory storage device at an average of approximately 300 to 1000 visual images per minute. , and that from a high-speed temporary memory storage device, the visual image information is written at a lower speed, but a larger capacity permanent memory storage device.

In addition, it is desired to provide the quality control process and / or apparatus that can continue to manufacture absorbent articles while collecting and displaying the visual images collected in real time and continuously, and that can send at least two sets of visual images to be stored in spaced periods of sufficient time, to allow high speed temporary storage, to write the entire set of images to permanent storage without interference from the second set.

It is also desired to provide the quality control process and / or apparatus including the placement of identification information on physical workpieces represented by the stored visual image information, thereby allowing the correlation of specific work pieces or products of the invention. absorbent article with specific visual images stored.

It is really desired to suspend the image storage, and store some of any of the images after the termination of any of the predefined sets of visual images, until the next activation event occurs.

In addition, it is desired, in some cases, to gather the visual images in two or more fixed locations along the trajectory of the manufacturing operations, in response to the activation events.

In this way, it is an object of the invention to provide the quality control process and / or the apparatus capable of monitoring the real-time condition of the articles that have been manufactured, and simultaneously, being able to selectively archive certain sets of items. Visual image data in a memory storage device.

Another objective is to archive in memory storage only that information that provides a higher average probability of containing information of interest to maintain quality control or for the development of engineering.

Also, it is another objective to send image information, preferably, as digital information, to memory storage, only when one or more activation cases related to the manufacturing operation occur and while the camera image recording is continuous.

It is also another objective that, upon occurrence of an activation event, the apparatus and / or process automatically sends preset images to the memory storage as visual image information.

It is also an objective that, during the time in which the visual image information is being sent to the storage, the visual image exposure is continuous, uninterrupted and unchanged, selecting and displaying images without being affected by the fact that the images visuals are being transferred to data storage.

It is also an objective to provide the quality control process and / or apparatus where visual exposure continues without decreasing before, during and after sending the visual images to storage.

Still furthermore it is a goal, to provide the quality control process and / or apparatus that first sends the visual image information so that it is stored in a high speed temporary memory storage device at an average capacity of at least about 300 to about 1000 visual images per minute, and from a high-speed temporary memory storage device, which writes the visual image information at a lower speed, but to a larger capacity permanent memory storage device.

In addition, it is an objective to provide the quality control process and / or apparatus that can continue to manufacture absorbent articles while continuously collecting and displaying the visual images collected in real time, and that can send at least two sets of visual images to storage. in periods of sufficient time spacing, to allow high-speed temporary storage, to write the entire set of images to permanent storage without interference from the second set.

Also, it is an objective to provide the process of quality control and / or apparatus that includes the placement of the identification information in digital images of specific work pieces so that in this way the correlation of specific work pieces or products of the product is allowed. absorbent article.

Also, it is a goal to suspend image storage, and store some of any of the images after finishing any of the predefined sets of visual images, until the next activation event occurs.

Still and in addition, it is an objective to gather the visual images in two or more fixed places along the trajectory of the manufacturing operations, in response to the activation cases.

SYNTHESIS OF THE INVENTION Some of the objectives have been achieved in the first family of embodiments of the invention comprising a method for using a visual imaging system in a manufacturing operation wherein the manufacturing operation produces a continuous flow of discrete fluids. The method produces the absorbent articles in a continuous web, and consists of the operation of a visual image system that assembles visual images in one or more places generally fixed in the manufacturing operation, usually bringing together discrete visual images at an average of minus 50 images per minute, preferably, but without limitation, up to about 1200 images per minute, in each fixed location, preferably at least and approximately 200 to approximately 1000 images per minute, more preferably and at least approximately 300 images per minute, still more preferably and at least about 400 to about 900 images per minute, and more preferably about 600 to about 800 images per minute. The method further provides a continuous visual image exposure of a pattern of consecutively assembled images, wherein each visual image represents a succession of at least one of the work pieces or a product, or a condition of the process, associated with the operation of manufacture. In addition, the method comprises the selection of one or more activation cases, planned or unplanned, related to the manufacturing operation, and when any of the activation cases occur, the continuous visual exposure of the image pattern continues, usually at the same time. Substantially average image collection, while simultaneously sending information representing a limited number of set of real-time visual images collected, to a memory storage device. The memory device must be a high-speed memory device such as a digital memory device, for example, a relatively high-capacity direct access memory (RAM) device or an intermediate memory device. The image collection rate can be adjusted as necessary at any time, even while the image information is being transferred from temporary storage to permanent storage.

Preferably, the method includes sending to the memory storage device at least some of the same visual images as exposed in the image display device.

The method preferably includes, upon completion of the sending of the image set to the digital memory device, continuing the continuous collection of visual images and hence continuing to provide a real-time visual image display of the pattern of images representing at least one of the pieces of work or product, or the process.

In preferred embodiments, the method includes writing the information of the visual image from the memory storage device to a second memory storage device of lower speed and with higher capacity.

The method preferably includes the synchronization of the image collection so that each sequential image assembled shows a complete length and a complete amplitude of one of the work pieces or product, or a condition of the process, per frame and one visual frame per piece of work or product, or process condition. Preferably, the sequential images represent work pieces or sequential products, or sequential process conditions.

Preferred methods include, while sending the set of visual images to the storage device, using the logic of the computer to analyze, in real time, the collected visual images, and send the corresponding results signals to the controlling apparatus that controls the manufacturing operation, and the control apparatus that processes the signals of the results and, based on the process of the signals of the results, emit the control commands so that by means of these they modify the manufacturing operation. The control command can, for example, modify the synchronization of a process step, or the result in the disposal of the work pieces from the manufacturing operation.

The method can, optionally, include continuing the function of the manufacturing operation upon completion of the sending of the set of the visual images to the memory storage device, and while the manufacturing operation continues to function, it sends a second set of a second number. limited of real-time visual images, said number may or may not be the same as the number of images in the first set, for the example of the digital memory storage device in response to a second activation case.

The method can include the incorporation of identification information with the complete digital image information stored representing the work pieces, thus allowing the correlation of specific images stored with specific work pieces.

Preferably, the method includes, after the completion of the sending of the set of real-time visual images and before a second activation event occurs, sending to the digital memory storage device, some or none of the visual time images. Real that meet.

Preferred embodiments of the method, preferably comprise the storage of images in digital format, including maintaining substantially complete digital integrity of the stored visual images, compared to the assembled images, and thereby substantially allowing total visual reproduction of the images. the visual images stored.

In some embodiments, the fixed location listed consists of a fixed first location, the set of visual images consists of a first set of visual images, and the method includes gathering visual images in a second location generally fixed in the manufacturing operation, in response to an activation case, and sending a limited number of the second set of real-time visual images thus assembled, to the digital memory, and optionally including separating the first and second set of the visual images from each other, in the device of memory storage.

The activation case that activates the sending of the second set of images to the memory, can be the same activation case that activates the sending of the first set of images to the memory. The sending of the second set of images to the memory storage may occur simultaneously with the sending of the first set of images to memory storage, partly simultaneously, or subsequent to the completion of sending the first set of images to memory storage.

Further, the invention comprises the apparatus for capturing, and simultaneously displaying and storing in memory, visual images of a process that produces effective absorbent articles for absorbing body fluids. The apparatus comprises manufacturing machines that manufacture the absorbent articles, the machines include the effective control apparatus for controlling operations of the manufacturing machines so that they make the absorbent articles according to the predetermined parameters: a visual image system that gathers images discrete real-time visuals in a generally fixed location in association with the machines manufacturing a workpiece or product, or a condition of the process, associated with the absorbent articles to be produced, and presenting a visual image exposure of time real of the assembled images, in an image display device, and the sending of signals of the corresponding results to the control apparatus, which controls by means of this the manufacturing machines: and a memory storage system that receives a number limited sets of real-time visual images, substantial less than all the visual images gathered and exposed by the visual image system.

In the preferred apparatus, the memory storage system comprises a high-speed temporary memory device, and a permanent memory storage device that receives the stored images from the temporary memory storage device.

The memory storage system preferably receives the set of visual images simultaneously with the exposure of real-time images on the exposure device. Preferably, at least some of the visual images received in the memory storage system are the same images that are simultaneously displayed in the image display device.

BRIEF DESCRIPTION OF THE DRAWINGS FIGURE 1 is a side elevational view of the apparatus for manufacturing the absorbent article of the invention, including a control system comprising a visual image subsystem comprising the apparatus for collecting, displaying and storing images and controls, as well as the interconnection of the visual image system with the control system of the manufacturing process and a memory storage system.

FIGURE 2 is a representative high end view, also substantially schematic, of some machines of the production line of FIGURE 1, used to make absorbent articles.

FIGURE 3 is a plan view illustrating a typical visual image exposed to the operator and stored in memory, and showing a portion of the manufacturing operation of the absorbent article.

The invention is not limited in its application to the details of construction or arrangement of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments or of being practiced or carried out in other different forms. Also, it should be understood that the terminology and phraseology used herein is for the purpose of describing and illustrating and should not be considered limiting. As a reference, numbers are used to indicate similar components.

DETAILED DESCRIPTION OF ILLUSTRATED REALIZATION FORMS With reference to the drawings, and more particularly to FIGURE 2, the numeral 10 designates a pair of side frame elements defining a process path extending longitudinally to the process of absorbent articles according to the invention. Rotationally mounted in the side frames 10 are a pair of process rollers 12 driven by wheels 16. The rollers of the process 12 of the drawing can be seen towards the left portion of FIGURE 1.

Now, referring to FIGURE 1, the production apparatus of the absorbent article of the invention is schematically illustrated at 18. Beginning at the left end of FIGURE 1, and extending below the fabric 20, for example a waterproof baffle the humidity is shown advancing to the right along with the longitudinally extending path, by the drawing of the rollers 12.

Omitted for clarity of presentation is the upper confining fabric such as a fabric lining the body.

The absorbent pads 24 are shown placed on the fabric 20 at spaced intervals generally corresponding to the respective separate and unbonded workpieces 25 or the products that are made within the absorbent articles along the processing path. Additional elements such as leg bends, retaining wings, hip bands, and the like, are placed, located and otherwise consolidated in or within the continuous web 20, or in or between one another, in several work stations along the processing path, in the manufacturing process of the absorbent articles.

For example, the unrolling 26 provides the material of the fold of the leg 28 which is placed on the cloth on the rollers 30. Similarly, the unrolling 32 provides the material of the hip band 34 which is placed on the fabric 20 on the rollers 36.

The chamber 38 is positioned between the work station defined by the rollers 30 and the work station defined by the rollers 36. The optional chamber 40 is positioned downstream of the rollers 36. The image activating device 42 is between the rollers. 30 and the camera 38. The image activation device 42 is between the rollers 36 and the camera 40. The image activation devices 41 and 42 are activated by detector, for example, by sensing the passage of a specific element in each. workpiece, for example an outwardly extending ear 44, illustrated in FIGURE 3. This activation provides a signal to the visual system 49 of the imaging system 48. The imaging system 48 includes the visual system 49, the temporary memory. 98, and the permanent memory 100. The visual system 49 includes the frame hoarder 46, the frame spacers 51, and the image analyzer 50.

The image activator sends detection signals to the frame grabber 46 and to the strobe lamp 57A and 57B. The detection signal thus synchronizes the flash of the respective strobe lamp and monopolizes the respective picture or image of the respective product by the box hoarder 46, being transmitted from the respective camera. The hoarded frame is transmitted by the frame hoarder 46 to the frame separator 51 in register with the movement of the respective work pieces in the production line, so that the frame hoarder transfers a visual image of each work piece of the frame. according to the detection signals created by the passage of respective work pieces that passed the image activation devices 41 and 42. While the image activation devices 41 and 42 are illustrated between the respective rollers and cameras, the devices activation could be anywhere in the processing line compatible with the timely collection of the pictures that are recorded by the camera or respective cameras.

The visual images are sent by the frame hoarder 46 to the frame separators 51, from there to the image analyzer 50 and, upon request by the activation case signal 102, to the temporary memory 98. After having been processed by the visual system 49, the processed signal of the camera is sent to the display device of the video image 52. The frame hoarder, the frame separator, the image analyzer, the temporary memory, and the permanent memory, all are elements of the imaging system 48 in the illustrated embodiment.

Referring to FIGURE 3, the closed profile 53 represents the field of view of the camera and it will be seen that the profile 53 covers more than the length of a single work piece 25, but less than the length of two work pieces. , generally positioned in the center of the profile 53, between the projected transverse separation lines 55A, 55B, which define the boundaries between the sequential workpieces.

A convenient imaging system for use in the invention, including the camera, the video image display device, the frame hoarder, and the image analyzer, is available to Cognex Corporation, Natick, Massachusetts, USA, as CHECKPOINT 800. Convenient software for collecting, displaying and analyzing the visual images collected from the individual items of the absorbent articles that are manufactured in the manufacturing operation are also made available by Cognex Corporation.

The visual image signals gathered by the camera 38 and the optional camera 40 are processed by the frame hoarder 46 and the image analyzer 50, by means of which it converts the images received from the camera or cameras into digitized representations of the images recorded visuals The results of the analyzes are fed to the process control 54. The process control 54 receives the signals of the results and issues the output commands, as appropriate, to adjust and modify the manufacturing process to rectify any anomaly readings and to direct the manufacturing operation towards the preselected target specifications stored in the process control memory.

In this way, the signals can be sent to accelerate, or decrease, the absolute speed, or to advance or delay the synchronization, of one or more steps of the process in respective work stations in the processing line. In addition, signals can be sent to discard the product from the processing line.

Referring again to FIGURE 1, the number 56 designates the main drive motor that drives the machinery that operates the production line of the absorbent article, whose main drive motor is used to rotate an axis of line 58 coupled by gearboxes 60, 62, for driving the rollers or rotating the rollers 64, 66 respectively.

The axis of the line 58 is also coupled by the gearbox 68 to the differential 70 which is operated by the motor 72 in response to signals from the process control 54 through a forward signaling device 74 or a signaling device. reverse signaling 76, both of which are coupled to the motor 72, to advance or delay the speed of the dragging of the rollers 36, and by means of this advancing or delaying the speed of the flow of the work pieces through the rollers 36, and according to this, the frequency in which the material of the hip band 34 is applied to the work pieces.

Similarly, the axis of line 58 is coupled by gearbox 78 to differential 80 which is operated by motor 82 in response to signals from process control 54 through signaling devices 74, 76, both of which are also coupled to the motor 82, to advance and delay the flow velocity of the workpieces through the rollers 30, and accordingly, the frequency at which the material of the leg fold 28 is applied to work pieces.

In addition, the axis of the line 58 is coupled by the gearbox 84, which contains wheels 16, to the differential 86 which is operated by motor 88 in response to signals from the process control 54 through the signaling devices 74, 76, both of which are also coupled to the motor 88, to advance or delay the driving speed of the work pieces 25 within the rollers 12, and according to this, the speed at which the fabric 20 and the elements resident therein are fed to the respective downstream work stations. After an image has been analyzed by the analyzer 50 and has been processed by the process control 54, a correction logic can be provided that personifies the range of acceptable specifications for the workpiece to the signaling devices 74 (forward ) and / or 76 (in reverse), or vacuum control 94 to discard the work pieces.

Additional work stations, not shown, may be employed in a similar manner to position and / or secure other elements of the absorbent articles, directly or indirectly, on the fabric 20.

The vacuum shoe 90 is placed on top of the work station 92 downstream of the chamber 40 and is controlled by the vacuum control 94. In circumstances where the signals received by the process control 54 indicate that the workpiece was reproduced and analyzed is out of tolerance, the process control 54 sends a waste signal 96 to the vacuum control 94, activating the vacuum for the vacuum shoe 90 at the appropriate time to discard the individual work piece that gives the information out of tolerance. Where desired, and where there is convenient driving time for the waste system, the vacuum control 94 can be programmed to discard, also, a specific number of work pieces before and / or after the workpiece. work produces the visual image information out of tolerance.

In addition to providing an output to the process control 54, the visual system 49 also produces the visual image information for the permanent memory 100. The information of the visual image produced from the visual system 49 to the temporary memory 98, and subsequently to the permanent memory 100, is sufficient in quantity and satisfactorily in quality and specificity, to generally recreate the individual visual images gathered by means of camera 38 and / or 40. In this way, the stored information substantially maintains total integrity, digital integrity normally complete of the stored visual images, as compared to the images recorded or collected by the camera 38 or 40. According to this, the stored visual images allow the user to substantially reproduce the respective images that were available to the operator in time. during the manufacture of the respective absorbent articles.

A convenient temporary memory for the use of the general purpose in association with the invention is a VME memory card having memory capacity of up to about 1 Gigabyte, and is available from Chrislin Industries Inc., Westlake Village, California, E.U.A. This temporary memory can capture, and store in memory, visual images of typical absorbent articles such as those described herein, in the high capture / storage rate of at least about 500 images per minute, up to about 1000 images per minute.

The communication between the communication system 49 and the temporary memory device 98 requires the use of a convenient protocol such as a standard VME to transfer information through the back plate of the computer to a temporary memory device. This temporary memory is an IEEE 1014 standard VMEbus.

While the high rate of image capture of the temporary memory 100 is critical to the invention, the high capture rate of the memory storage devices have certain limitations. First, these devices are costly in terms of the cost per image captured and stored. In addition, devices with high capture rate such as the buffering devices described above are temporary memory storage devices within the context of which, said storage devices retain information captured in the memory only for the time that the respective device of Memory is on, and it loses all the information stored in the memory when said memory devices are disconnected.

Accordingly, it is critical that the visual image information received in the high-speed temporary memory storage device, eg, buffer, be transferred to a permanent memory storage device. A convenient permanent memory storage device is, for example, a hard disk equal to the hard drives commonly used in personal computers. Where a greater amount of memory is desired instead of what is available on a conventionally available hard disk, a combination of these hard disks can be coupled together in a well known manner, so that by this the composite capacity of all hard drives coupled together.

The value of the temporary memory device 98 is to allow the real-time transfer of the information of the visual image from the image system. Conventional permanent memory devices are very slow for that real time transfer at any reasonable interconnection cost, by means of which the temporary memory device is used.

The value of the permanent memory 100 is triple.

First, once the information has been received into the permanent memory, the permanent memory can be accessed by a variety of users, if desired, through a normal system of interconnection of computers that work by network. Second, the permanent memory retains the information in the memory when it is turned off and where it is disconnected from the storage device of the permanent memory, and is lost. In this way, once the visual image information is placed in the permanent memory, the risk of loss due to elimination or interruption of the connection is eliminated. Third, the permanent memory is less expensive than the temporary memory, for example, the buffer.

Accordingly, the images that have been conventionally available only to the operator in the production line, and that have been available only as real-time images, are, by virtue of the invention, now available at any time, for anyone who has access to the permanent memory device, as well as from a remote computer terminal from a network access 106.

Similarly, the information stored in the process control 54 can be registered and accessed from a remote terminal, through the network access 106, in this way direct correlation and comparison of specific images with control information of the specific process is allowed. In this way, in the invention, the images remain available for real-time use in the production line, as before: and can, in addition, be accessed whether the production plant is turned on or off at a later date by any authorized user, for further analysis at any desired level of analysis.

In this way, for the first time, the visual images of the product, or of the process, can be permanently archived, and associated with specific manufacturing periods or specific manufacturing events, without interrupting the continuous collection of the visual images. In addition, the visual images stored in memory can be recreated from the information stored in the same or in another visual system, or they can be stored and reused in other software applications as well as in combination with bitmap systems. In any case, the information stored and recovered later can be used for a deep analysis of the results, in the work pieces, of specific cases that occur in the production line.

The individual images recorded or received in the cameras 38 and 40 and finally stored in the permanent memory 100, can be individually accessed at will from the permanent memory 100, and analyzed as desired, at any time after the collection. For example, an analyst may choose to review and analyze a certain set of images based on the occurrence of an activation case, or a set of images recorded according to the time in which the images were collected.

As is well known, for the use of computer memory devices, the visual image information that is stored permanently, for example, in the permanent storage device 100, can be erased at will to make the available storage space to use it. to store other information.

The image system 48 described above has an average capacity capable of producing a visual image of each and all of the work pieces produced by the manufacturing operation. In fact, the line operator expects the image system to produce a visual image of each and every work piece.

Either way, you do not want to store a visual image of each and every work piece. The storage of all the visual images produced would require an immoderate amount of memory storage capacity. Moreover, since the production rate of said images is greater than the average input capacity of a permanent memory storage device of the normal hard disk to receive said information, the storage would have to be carried out in parallel with multiple devices. permanent memory simultaneously receiving memory storage entries. In addition, the amount of information stored in memory would make it difficult for a researcher to identify images of particular interest for further study and / or to correlate any of these images with specific cases in the manufacturing process.

Accordingly, it is an important feature of the present invention that, the visual images are transferred from the image analyzer 50 to the memory storage device as well as the temporary buffer 98, only upon occurrence of selected, preferably predetermined, activation instances. . By limiting the transfers to the memory of only those images associated with certain activation cases, the amount of storage media required is adequately limited, and the amount of information stored, and that can be reviewed to find evidence of a case of interest, it is also limited.

The suggested Cognex Imaging system can be programmed to transfer a specific number of visual images to memory upon the occurrence of an activation case. The transfer can start so that it takes samples where the workpiece that is being seen when the activation occurs is at or towards the beginning of the sample, in the middle of the sample, or at or towards the end of the sample .

The user can specify any event of interest as an activation case for the collection of visual image information. For example, a splice in any of the fabrics fed 20, 28 and 34, must be specified as an activation case. A certain amount of change in line speed must be specified as an activation case. A certain amount of change in the tension of one or more fabrics, must be specified as an activation case. An out of tolerance condition must be specified as an activation case. Additionally, manual activation can be used to start capturing images, as can be done with a stopwatch, or a random number generator.

In any case, the activation case is created, the manufacturing controls are configured such that, upon occurrence of an activation event, a signal 102 is generated, for example, by means of a sensor or by means of a process control command , and it is transmitted to the visual system 49, activating the image separator 51 to initiate the sending of visual images to the memory, and to specify how many images are sent to the memory, or to know how long the image time period is to be sent to memory.

In this way, upon occurrence of an activation event, a defined set of a limited number of real-time visual images gathered by the frame hoarder 46 is sent to the visual system 49, hence to the temporary memory device 98. Preferably, while the information is still received by the memory device 98, the memory device 98 begins to transfer the information of the visual image to the permanent memory device 100 at the slowest rate at which the permanent memory device is capable of receiving and store said information.

According to this, in preferred embodiments, the part of the visual image information has already been transferred to the permanent storage device 100 by the time in which the last of the sets of images has been received in the memory. high speed 98. According to this, the memory device 98 acts as an accumulator to temporarily take the excess volume of visual images that are transferred from the visual system 49, until the memory device 100 can receive the total of the set of pictures .

If a second activation case occurs before the last of the first set of images has been transferred to the memory device 100, the permanent memory device 98 receives the second set of images, and transfers that second set of images to the memory device 100 after finishing the transfer of the first set of images. In some embodiments, the first set and the second set of visual images are separated from one another, as separate and distinct sets of image information, in at least one of the respective memory storage devices.

Upon completion of the transfer of a given set of visual images according to the activation case, preferably no further visual images are transferred to the memory devices 98 and 100 until the next activation event occurs. While a few visual images can be transferred to the storage memory for the purpose of keeping the historical record, for example, keeping a historical record of the product made and / or sent, the frequency in which said images will be stored is significantly lower, that is, less than 10%, preferably less than 2%, as frequent as the frequency with which said images are stored upon occurrence of an activation event.

A normal image set includes images of approximately 1 to approximately 1000 consecutive work pieces in the processing line. An index of about 1 to about 200 workpieces is contemplated for normal use in the invention. If a smaller number of work pieces are stored than those mentioned, the evidence of the activation case could be lost. If a greater number of the work pieces are stored than those mentioned, the storage costs would be increased immoderately, also the memory of the computer, and could create a database so large that finding useful information could be very difficult, or so less inefficient.

The illustrated embodiments indicate the use of one or two cameras 38 and 40. Normally, the use of a camera is suitable to indicate the strengths or weaknesses of the manufacturing operation. Either way, where there is an anomaly, or it is difficult to correct, additional cameras, such as the camera 40, should be placed in the corresponding additional places along the manufacturing line, and connected within the image system 48, and the memory system (device 98 and device 100), to gather and permanently store the additional information directed towards the discovery of the source of the anomaly. According to this, the imaging system can produce and store a second set of data in memory, either before, for example, slightly before, during, or after, for example, slightly later, by gathering and storing a first set of data. . The second data set can be obtained from the same camera, for example, directed to the same place on the processing line, as the first data set, or can be obtained from a second camera directed to the same place on the processing line or can be be located in a different work station, recording a different step in the process.

By associating the appropriate identification indications with each transfer of a set of visual images for storage, the person carrying out the review can first look for the identification indications, and have found the identification indications, and then can focus in the parameters of interest associated with the respective visual images.

Where it is desired to correlate specific physical samples to the visual images of the samples, a specific code of the article, different for each coded workpiece, can be printed on the respective work pieces 25, such as, for example, on the ear 44 Said code can be printed by, for example, a contactless inkjet printer 104 located upstream of the respective chamber. In the alternative, a common code, specific to the activation case, can be printed on each of the work pieces associated with the activation case.

While not critical to the invention, it is preferred that the visual images sent to the memory devices 98 and 100 are the same images sent to the exposure device 52. In this case, the images available for review later, are the same images reviewed by the operator in real time.

The invention has been described above generally in terms of known or planned activation cases. Either way, the image system 48 can be programmed to store the activation of visual images in memory upon occurrence of a wide variety of unplanned cases, for example, any occurrence of any case out of tolerance, or any unforeseen event.

In some embodiments, the camera or video cameras take visual images of an amount less than all of the work pieces that will be processed in the manufacturing operation. When desired, a camera can be programmed to collect images of each second workpiece, of each third workpiece, or any other desired fraction of the workpieces. Said selection can gather images at regular intervals, or at selected intermittent intervals. For example, a camera control should be programmed to order the taking of images of a certain set or number of sequential work pieces, for example, 3 work pieces, then skip the next set of work pieces, for example, 5 pieces of work. The current interval between the work pieces from which the image was recorded, and the pattern from which the images of the work pieces should be gathered, is a matter of selecting the person who places the image collection.

As used herein, the "absorbent article" refers to a class of products for use in the human body, and generally used for the promotion of human hygiene by absorbing body fluids and other emanations. Some examples of such absorbent articles include, without limitation, diapers, trainers, incontinence towels, sanitary napkins, interlabial towels and the like.

As used herein, a "high-speed" memory storage device is a device capable of receiving at least about 50, preferably at least about 200, and more preferably at least about 300, and still more preferably at least about 400 or 500, up to at least about 1200 visual images per minute from the chambers of the nature described herein, for use in the invention, and should be able to track the production rate of the unit of the products of interest for the imaging system. Commonly available are these memory devices, which are known by several as Direct Access Memory (RAM) devices, and / or Intermediate Memory devices, both of which are well known in the art. Normally available memory storage devices, which retain information only for as long as such devices are turned on, and where any information stored in them is lost when the electrical power is terminated. According to this, these memory devices are not convenient for permanent data storage. Rather, in the invention, the information is written from the high-speed temporary storage device to a lower-speed permanent memory storage device.

The number of images collected per minute is controlled by signals, from the processing line, indicating the frequency of the passage along the processing line of the work pieces from which the images are collected.

As used herein, a "lower speed" memory storage device is any memory storage device that is unable to receive visual images of the products of the absorbent article class., from the image separators 51 of the nature described herein, for use in the invention, typically at a rate of less than about 500 visual images per minute. Normally, memory devices are hard disks similar to those commonly used in personal computers. These hard drives are available in a variety of sizes, and in a range of input speeds, where large amounts of image information can be easily stored in permanent memory, at a reasonable cost per image.

The number of images that can be transferred over a given unit of time, is a function of the complexity of the image inspections, and the resolution of the images. The more complex the image inspection is and / or the higher the resolution of the image, the slower the capacity of the transfer index of the visual system 49.

As used herein, the reference of the "generally fixed" location, where the visual images are put together, means that the image gathering element such as a camera is fixedly mounted to a physical support, and is directed to a step or specific step in the manufacturing operation. In this way, "generally fixed" refers to a fixed camera in one place, but with the ability to quickly zoom in digitally or optically to the image to facilitate the inspection of certain elements of the workpiece or work pieces, while that the camera does not move from the place where it is mounted. The cameras can, of course, be moved and subsequently recalibrated.

Preferably, the camera is fixed at both a location and direction of the lens, so that the sequentially gathered images represent a common place and common objective direction of the camera.

As used herein, the "image pattern" refers to a continuous selection of images according to a selection pattern. The selection pattern can select, and therefore, gather a specific image for each piece of work, product or condition of the process. The selection pattern can, in the alternative, select and assemble an image according to an alternative pattern, for example, gathering an image of each second or every third piece of work, product or condition of the process, or gathering an image of each workpiece, product or process condition, for a limited number of images, at regularly spaced interv The patterns described above are only exemplary, and not limiting, as other patterns are now obvious and feasible in the invention.

Those of skill in the art will now see that certain modifications can be made to the apparatus and methods disclosed herein in relation to the illustrated embodiments, without departing from the spirit of the present invention. And while the invention has been described above in relation to the preferred embodiments, it will be understood that the invention is adapted to numerous new arrangements, modifications and alterations, and all these arrangements, modifications and alterations are intended to be within the scope of the invention. attached claims.

To the extent that the use of the following claims means more language of the functions, it is not said to include there, or in the present specification, anything that is not structurally equivalent to what is shown in the embodiments disclosed in the specification.

Claims (34)

1. A method using an imaging system in a manufacturing operation, wherein the manufacturing operation produces a continuous flow of discrete absorbent article work pieces and products made thereof, effective for absorbing body fluids, the method that produces the absorbent articles of a continuous fabric, and comprising: (a) operating a visual image system that brings together visual images in the manufacturing operation and, through this, brings together discrete real-time visual images at an average of at least 50 images per minute, and provides a continuous visual image exposure of a pattern of images representing at least one of the work pieces or a product, or a condition of the process, associated with the manufacturing operation; (b) select one or more activation cases, planned or unplanned, related to the manufacturing operation; and (c) upon occurrence of any of the activation cases, continuing continuous visual exposure of the consecutive images of the consecutive work pieces to be processed while simultaneously and automatically transmitting information representing a limited number of sets of the visual images of real time gathered to the memory storage device.

2. A method according to Claim 1, which includes sending to the memory storage device at least some of the same visual images as exposed in the image display device.

3. A method according to Claim 1 including, upon completion of sending the image set to the digital memory device, continuing the continuous collection of the visual images as in step (a) and by means of this continuing to provide a visual image exposure Real-time continuous image pattern that represents at least one of the work or product parts, or the process.

4. A method according to Claim 1, which includes writing the information of the visual image from the memory storage device to a second memory storage device of lower speed and greater capacity.

5. A method according to Claim 1, which includes sending the discrete visual images to the memory storage device at an average of at least 200 images per minute.

6. A method according to Claim 1, which includes sending discrete visual images to the memory storage device at an average of at least 300 images per minute.

7. A method according to Claim 1, which includes sending the discrete visual images to the memory storage device at an average of at least 400 images per minute.

8. A method according to Claim 1, which includes the synchronization of the image collection in such a way that each sequential image shows a total length and a total amplitude of one of the work pieces or product, or a condition of the process, and an image Visual per piece of work or product, or condition of the process.

9. A method according to Claim 7 wherein the sequential images represent sequential work pieces or products, or sequential process conditions.

10. A method according to Claim 7 which includes, while sending the set of visual images, having complete digital integrity, to the storage device, using the logic of the computer to analyze, in real time, the visual images collected, and send the Signals of the corresponding results to control the apparatus that controls the manufacturing operation.

11. A method according to Claim 10, which includes the manufacturing control apparatus that processes the output signals and, based on the processing of these output signals, issues a control command to modify the manufacturing operation by this.

12. A method according to Claim 11, wherein the control command modifies the synchronization of a process step.

13. A method according to Claim 11, wherein the control command stops the manufacturing operation.

14. A method according to Claim 11, wherein the control command provides an alarm to an operator.

15. A method according to Claim 11, wherein the control order results in the disposal of work pieces from the manufacturing operation.

16. A method according to Claim 1, which includes continuing to operate the manufacturing operation upon completion of sending the set of visual images to the digital memory storage device, and while continuing to operate the manufacturing operation, send a second set of a number limited real-time visual images to the digital memory storage device in response to the second activation case.

17. A method according to Claim 1, which includes the incorporation of identification information with the stored complete digital image information representing the work pieces, thus allowing the correlation of specific visual images thus stored with specific work pieces.

18. A method according to Claim 1, the method includes, after the completion of the sending of the set of real-time visual images and prior to the occurrence of a second activation case, the sending to a digital memory storage device of some or none of the real-time visual images that came together.

19. A method according to Claim 1, which includes substantially maintaining the complete digital integrity of the stored visual images, compared to the collected images, thereby allowing substantially and completely visual reproduction of the stored visual images.

20. A method according to Claim 1, wherein the fixed location comprises a first fixed location, the set of visual images comprises a first set of visual images, and includes the collection of visual images in a second location generally fixed in the manufacturing operation, in response to an activation case, and sends a second set of limited number of real-time visual images gathered in the digital memory.

21. A method according to Claim 20, which includes separating the first and second set of the visual images from one another in the memory storage device.

22. A method according to Claim 1, wherein the memory storage device is a digital memory storage device.

23. A method according to Claim 22, wherein the digital memory storage device is a temporary memory storage device, and includes the transfer of visual images from the temporary memory storage device to the permanent memory storage device.

24. A method for using an imaging system in a manufacturing operation wherein the manufacturing operation produces a continuous flow of discrete absorbent article work pieces and products made thereof, effective for absorbing body fluids, the method that produces the articles absorbents from a continuous fabric, and comprising: (a) assist in the control of the manufacturing operation, operate a system of visual images and through this gather discrete real-time visual images at an average of at least 50 images per minute, and provide a visual image exposure continuous of a pattern of the images representing at least one of the work pieces or a product, or a condition of the process, associated with the manufacturing operation; (b) continue the continuous visual exposure of continuous images of continuous work pieces that are processed while 10 automatically and simultaneously the information representing the complete digital images of a limited number of sets of the real-time visual images gathered is sent to a first device of 15 permanent memory storage; (c) extract limited information from the complete digital images and store the limited information in a second 20 permanent memory storage device; (d) making available both the complete digital image, and the extracted information limited to a network access device, and (e) having access to the complete digital image in the first permanent memory storage device from a remote computer terminal from the network access device.

25. A method according to Claim 24, which includes accessing the limited information in the second permanent memory storage device while accessing the complete digital image, in the same computer terminal.

26. A method according to Claim 25, which includes comparing the limited information from the second permanent memory storage device with the complete digital image from the first permanent memory storage device in the remote computer terminal.

27. A method using an imaging system in a manufacturing operation, wherein the manufacturing operation produces a continuous flow of discrete absorbent article work pieces and products made thereof, effective for absorbing body fluids, the method that produces the absorbent articles of a continuous fabric, and comprising: (a) operate a visual image system that brings together visual images in the manufacturing operation and by means of this it assembles discrete visual images at an average of at least 50 images per minute, and provides a continuous visual image exposure of a pattern of the images representing at least one of the work pieces or a product, or a condition of the process, associated with the manufacturing operation; (b) select one or more activation cases, planned or unplanned, related to the manufacturing operation; Y (c) upon occurrence of any of the activation cases, continuing continuous visual exposure of the image pattern, while simultaneously sending information representing a limited number of sets of real-time visual images gathered, to a temporary memory storage device of high speed, and includes the transfer of visual images from a temporary memory storage device to a memory device of lower speed, but permanent.

28. The apparatus for capturing, and simultaneously displaying and storing in memory, visual images of a process that produces effective absorbent articles to absorb body fluids, this apparatus consists of: (a) manufacturing machines for producing the absorbent articles; (b) effective control apparatuses for the control operations of the manufacturing machines so as to produce the absorbent articles according to a range of predetermined parameters; (c) an imaging system that assembles discrete real-time visual images, in a generally fixed location in association with the machines for manufacturing a workpiece or product, or a condition of the process, associated with the absorbent articles that are they produce, and which present a real time visual image exposure of the assembled images, or an image display device, and send the corresponding results signals to the control apparatus, to control by means of this the manufacturing machines; Y (d) a memory storage system that receives a limited number of sets of the real-time visual images, substantially less than the totality of the visual images collected and displayed by the image system.

29. The apparatus according to Claim 28, wherein the memory storage system consists of a high-speed temporary memory storage device, and a permanent memory storage device that receives the stored images from the temporary memory storage device.

30. The apparatus according to Claim 28, wherein the memory storage system receives the set of visual images simultaneously with the display of real-time visual images on the image display device.

31. The apparatus according to Claim 28, wherein the memory storage system receives, as the set of visual images, at least some of the same visual images as set forth in the image display device.

32. The apparatus according to Claim 29, wherein the memory storage device receives the discrete visual images at an average of at least 200 images per minute.

33. The apparatus according to Claim 29, wherein the memory storage device receives the discrete visual images at an average of at least 300 images per minute.

34. The apparatus according to Claim 29, wherein the memory storage device receives the discrete visual images at an average of at least 400 images per minute. SUMMARY The apparatus and method that uses the visual image for the short-term and long-term monitoring and control of a manufacturing operation which produces absorbent articles to absorb body fluids. The system assembles discrete real-time visual images at an average of at least 50 to 400 images per minute, up to at least 1200 images per minute, provides a continuous exposure of a pattern of images, and upon occurrence of an activation event , continuous visual exposure of images while sending information representing a limited number of sets of real-time visual images to a memory storage system that permanently receives and stores information for future retrieval. Preferably, the information is received in a temporary memory device, and written from there to a second permanent memory device. While the visual images are sent to the memory storage system, the process control logic preferentially analyzes the visual images in real time, and sends the signals of the results to the manufacturing control, which modifies the manufacturing operation , for example, modifies the synchronization of a process step, interrupting the process or discarding the work pieces. A second set of a second limited number of the visual images may be sent to the memory system in response to a second, optionally subsequent, case of activation and / or from a second location. After sending any set of real-time visual images to memory storage, and before a subsequent activation event occurs, preferably, the images are collected, received continuously, but some or none of the images are sent to the device. memory storage. The collection of images is preferably synchronized with the progress of the work pieces or the product or the steps of the process along the line of the manufacturing process.