MXPA01006644A - Process control using multiple detections - Google Patents

Abstract

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

Description

PROCESS CONTROL USING MULTIPLE DETECTIONS BACKGROUND This invention relates to an apparatus and methods for automatically monitoring and evaluating manufacturing processes and articles made by manufacturing processes. The invention relates to, for example, operations, which produce an ongoing stream of products such as discrete absorbent articles, for example, disposable diapers, effective to absorb body fluids. These absorbent articles are usually manufactured as a sequence of work pieces that are proceeding in a continuous pattern, generally operating in a processing line. These absorbent articles generally comprise an absorbent core confined between a moisture impervious screen of, for example, polyethylene and a body-permeable moisture-permeable liner of, for example, fibrous material and a fabric. The absorbent articles are generally made by advancing one of the wefts along a longitudinally extending path, applying the absorbent core to the first of the wefts and then applying the second weft on the combination of the first weft and the absorbent core. Other elements are added such as elastics, leg cuffs, restraining wings, hip bands and the like, as desired, for the particular product being manufactured, either before, during, or after applying the second weft, these elements may be oriented longitudinally along the trajectory, or transverse to the trajectory, or may have a neutral orientation.

Normally these manufacturing processes are designed to operate in a stable state in a predetermined setting of operating conditions. While this process is in operation under steady-state conditions, the desired result of the process is conveniently and typically achieved. For example, when the process is designed to produce a particular manufactured item, customarily manufactured articles are produced when the process is operating under specified conditions of steady state.

As used herein, "steady state" conditions represent more than a single specific series of processing conditions. Rather, "stable state" represents a range of specified processing conditions which correspond to a high probability that acceptable articles will be produced, mainly that the products produced will correspond to the specified parameters of the products.

While a conventional process is in operation, the sensors and other monitoring apparatus are normally used individually at several sites along the processing line to automatically detect several respective parameters with respect to the article being manufactured and to supervise the condition of the same in another way. For example, in a diaper manufacturing operation, a sensor such as a photoelectric cell can be used to detect the presence or absence of a particular element of the diaper such as an ear, the edges of a hip band, the edge or edges of a absorbent core, or similar. In addition, a visual image reproduction system can be used as another form of sensor to detect and / or measure important dimensions or components in the units of the articles being manufactured.

Analytical models and known control models are based on assumptions that the errors related to these detections, collections and records are insignificant and thus that all the determination signals, or in the absence of said determination signals, including the Quantitative signals, as well as the visual images and the analysis measurements of images made thereof, are in fact accurate representations of the elements that are supposedly being detected and / or measured.

Nevertheless, the actual operation of many manufacturing processes, including highly automated processes, generally includes the occurrence of newspapers, and in some cases numerous, errors, inaccuracies, or omissions in the determination signals and / or the visual images. These errors, inaccuracies, or omissions can be caused by a variety of factors. These factors may be, for example, and without limitation, catastrophic sensor failure, intermittent sensor failure, sensor calibration error, a temporary "out of calibration" condition of the sensor, an effective obstruction between the sensor and the sensor. element that will be detected, or a loose or broken connection between the sensor and the computer or other controller to which the sensor is connected. Generally, these factors also apply to systems of reproduction of visual images, including lighting or camera, as well as numerous irregularities of products, components and processes.

A variety of possible events in the manufacturing operation can result in the manufacture of product units that fall outside the range of specifications. For example, with reference to the manufacture of absorbent articles, the stretchable materials may stretch less than, or more than, the desired amount. The elements may be misaligned in relation to the correct registration in the manufacturing operation, or bending, wrinkling, undulating, or twisting in an inappropriate manner. The synchronization between the steps of the process, or the speed of advancement of the element, can be lost from the target ranges. If non-catastrophic changes in process conditions can be detected in a rapid manner, process corrections can usually be made and variations in target conditions can consequently be controlled in such a way that the product remains within the ranges of specifications affected, without having to stop the manufacturing operation and preferably without having to select and therefore dispose of the product.

A variety of automatic product inspection systems are available to carry out routine automatic on-going inspections of the product being produced in a manufacturing line and to take samples periodically and automatically for the manual evaluation of backup. In fact, periodic manual inspection and evaluation of product samples are still important as a final guarantee that a quality product is being developed. However, in high-speed manufacturing processes, the main tool for on-going inspection of products is one or more automated computer-controlled inspection systems which, automatically, mainly without direct human intervention, inspect the product that is being inspected. is manufacturing, preferably inspecting each unit of said product.

When the product is outside the range of specifications affected and must be selected, you want to select all the defective product, but only that product which is in fact defective. If very little product is selected, or if the wrong product is selected, then the defective product is freed improperly for shipping. On the other hand, if the product is selected which in fact complies with the product specification, then acceptable and highly valuable product is being discarded.

Absorbent articles that absorb body fluids as are of interest herein to implement the invention are typically manufactured at speeds of 50 to 1200 items per minute in a given manufacturing line. Consequently, and especially at higher speeds, it is impossible for an operator to manually inspect each and every one of the absorbent articles thus produced. If the operator reacts in a conservative manner, selecting products every time he has a suspicion, but no solid evidence, that a product does not meet the specifications, then a considerable amount of product will have been selected in fact in good condition. In contrast, if the operator acts only when a defect has been confirmed using visual inspection or other manual inspection, the defective product may have already been released to the trade stream before the defective condition has been confirmed.

One way for the operator to inspect the product for compliance with the range of specifications is for the operator to periodically randomly collect samples of the product being manufactured and inspect those samples randomly off-line. In these random inspections there is very little chance of detecting temporary conditions that are outside the specifications. On the other hand, when the operator takes samples in response to a supposed condition that is outside the specifications, given the high speed at which such items are manufactured, by the time the operator finishes the inspection, the alleged offensive condition may have existed for a long time so that a substantial amount of questionable or defective product has been shipped or selected without that the operator had a solid base on which to make the decision of shipment or selection. In addition, automated controls of the manufacturing process may have self-corrected the defective condition before the operator can take the samples or before the operator can complete the visual / physical inspection and act on the results of such visual inspection. In this way, conventional manual inspection by an operator, while providing the highest level of inspection quality potential, is unlikely to effectively monitor and control temporary conditions outside of the specifications, or Proactively control the processing conditions that could produce items outside the specifications, in processes that produce products at the rates specified above.

While off-line inspection can be a determinant of quality and generally defines the final quality and disposition of product groups, online inspection and on-line evaluation of data collected online, usually associated with Certain manufacturing events can provide valuable insight into both the operating characteristics of the manufacturing process and the final quality parameters of the product, as well as discernment on possible proactive improvements which could be made in the control of the process.

In this way, in processes that operate at speeds such that the manual inspection of each product unit is an unreal expectation, the main mechanism for inspecting each product unit is one or more automatic computer controlled inspection and control systems, optionally including a system of reproduction of visual images, backed by periodic manual inspections of physical samples, or sample images, of product to confirm the precision of the decisions that are taken by the automatic inspection and control systems. These automatic inspection and control systems automatically inspect, mainly without direct human intervention, the product that is being manufactured, preferably inspecting each unit of said product.

The automatic inspection and control systems depend on a plurality of detection devices and analytical tools to detect a corresponding plurality of different pre-selected parameters, qualitatively and generally quantitatively, in the articles that are being produced. These preselected parameters are selected for their representation prospects of the general real grade in which the articles conform to the preselected specifications. The conclusions made and the control actions taken on the basis of said conclusions are only as reliable as the termination signals created and / or developed by the detection devices and analytical tools. The reliability of these determination signals is therefore critical as regards the ability of the automatic inspection and control system to sufficiently and effectively control the manufacturing operation.

While sensors and analytical tools are readily available for use and automatic systems of inspection and control, these sensors and analytical tools must be handled with care, be it placed, installed, calibrated, programmed, etc., and thus remain in the middle of manufacture.

As a practical matter, these sensors and tools will develop and / or transmit erroneous determination signals periodically, even when handled by a regular maintenance program. In normal situations, the inspection and control system is unable to detect the fact that these signals are erroneous signals, by which the inspection and control system fails to respond, erroneously, as if the signals were, in fact, accurate or failures not responding at all. While the general purpose of the automatic inspection and control system is to minimize the shipment of defective products, this erroneous response may in fact result in the control system causing the product to be out of specification. Mainly, an error in the control system can actually result in the release and shipment of the product that does not meet the ranges of specifications affected. Therefore, it is critical that the incidence of errors, particularly erroneous determination signals, be limited as much as possible.

As indicated above, there are both advantages and limitations in terms of automatic inspection and control systems. An important advantage of these systems is that the speed of the automatic analysis allows these systems to inspect each and every one of the units that are being developed in the manufacturing lines that operate at the suggested speeds. These automatic inspection and control systems are required when the rate of product manufacture exceeds the rate of reasonable human / manual inspection, even allowing many people to perform inspections.

A limitation of automatic inspection and control systems is that, while these systems may conventionally have the ability to distinguish an accurate signal from the determination of an erroneous determination signal, they can not compare, correct, or compensate for erroneous signals. In addition, these conventional systems inspect only a limited part of the product. And while the wrong signals and readings do not happen often enough to suggest that these automatic inspection and control systems have no net value, to the extent that the incidence of erroneous signals can be reduced, or to the point where it can be reduced The incidence of acceptance of erroneous signals as accurate representations of the general condition of the product, the value of these automatic systems of inspection and control will be improved.

An objective of this invention is to provide improved inspection and control systems and methods of measuring product parameters to increase the reliability of the decisions made from the processing of the determination signals created and / or developed by these inspection and control systems. .

Another objective is to provide inspection and control systems and methods of use, which effectively analyze the determination signals and automatically correct certain signals and defective signal conditions.

Another objective is to provide inspection and control systems and methods of use, which effectively modify the input of determination signals when the control system detects a defect in the signal.

Another objective is to provide inspection and control systems and methods of use, which detect sensors and / or analytical tools that are out of calibration and automatically recalibrate these sensors and / or tools.

Another objective is to provide inspection and control systems that automatically implement the back-up inspection of the items associated with the defective determination signals.

A general objective is to provide inspection and control systems that reduce the incidence of erroneous signals that are provided to the controller of the manufacturing operation.

A more specific objective is to provide inspection and control systems that reduce the incidence of erroneous signals that are accepted as accurate by the controller of the manufacturing operation.

SUMMARY This invention contemplates a method for measuring a parameter of articles that are processed in a manufacturing operation. The method comprises the establishment of an objective parameter that will be measured in the articles and acceptable conditions of the objective parameter. The method develops a measurement strategy for measuring the target parameter and detects and measures the target parameter with respect to at least the first and second separate replica and distinct determinations of the condition of a segment of the articles using at least one of the multiple independent determiners or a common determiner taking multiple determinations at corresponding sites in the article. Each of the sites conveniently indicates a common acceptable condition of the target parameter. Therefore, the method develops at least the first and second separate and distinct replication determination signals as representations of the target parameter. After developing the measurement strategy the method contemplates the programming of a programmable device to use a suitable analysis method to evaluate the determination signals, transmitting the determination signals to the programmable device for analysis and processing the determination signals in the programmable device to use the respective analysis method to analyze the determination signals thus received, in accordance with the established acceptable conditions.

Some embodiments include detection of the target parameter with respect to at least the first and the second separate and distinct replica of determinations for at least the first and the second parameter at respective replica sites in the articles.

Some embodiments include the processing of the determination signals to use the different first and second analytical methods to analyze the determination signals representative of the respective first parameter and the second parameter.

Some embodiments include the detection of the target parameter with respect to at least the first, second and third separate and distinct replica of condition determinations of the items, optionally each for at least the first and second parameters at sites of respective replica in the articles, optionally including the processing of the determination signals of the first respective parameter and the second parameter to use the respective first and second respective analytical methods to analyze the determination signals representative of the respective first parameter and the second parameter.

The methods may include detection of the target parameter using the first and second separate and distinct sensors, optionally selected from the group consisting of photoelectric sensors, infrared sensors, motion sensors, temperature sensors, vision cameras and ultraviolet sensors and other sensors of visible spectrum light.

A variety of analytical methods can be used to process the determination signals, for example by calculating an average of, for example, three or more signals, determining the number of common or nearly common magnitude signals or other characteristics, or calculating a standard deviation based in the determination signals. When the processing and / or analysis, optionally including human analysis, of the determination signals comprises the conclusion that one of the determination signals is transmitting an erroneous message, the method may include, automatically and in accordance with the programmed instructions, the modification of the signal combination to compensate for the wrong signal.

Signal processing may include comparison of the signals either alone or in combination with a dase of combinations of known and / or expected signals. This dase optionally includes a historical probability of the occurrence of some of the respective combinations. Based on the comparison of the determination signals with the dase of combinations of signals, the method develops a conclusion as to the possible cause of some anomaly in the combination of signals and develops a corresponding response to the combination of signals. This anomaly can, for example and without limitation, represent anomalies in the product that is being manufactured, anomalies in the detection of the parameter of interest, anomalies in the reception and / or processing of the sensor of the detection of the parameter, anomalies in the adjustment of the sensor, anomalies in sensor calibration, etc.

The methods may include transmitting the calculated response as a control signal to a process controller that controls the manufacturing operation and therefore to process control devices that physically make adjustments to the operation of the manufacturing process.

The methods may include, when the analysis detects a condition that is out of calibration in one of the multiple independent determiners, the automatic recalibration of the "out of calibration" determiner, in time, or intensity, or both.

Methods may include, when the analysis detects the inadequate entry of one of the multiple independent determiners, the automatic adjustment of the analysis to a lower determiner base, and / or the automatic implementation of the back-up inspection of items associated with inadequate input. .

The invention generally comprises a manufacturing operation wherein a manufacturing line has a plurality of work stations, mainly places where a process or inspection is performed on a work piece and wherein the first and second replica can be taken at said work station. of common work, or where a second replica is taken at a work station separate from, for example, downstream of, the work station at which the first replica is taken. Normally, the method includes the analysis of each and every unit of the articles in the manufacturing line.

In a more specific family of embodiments, the invention comprises a method for measuring a parameter of articles that are processed in a manufacturing operation. The method comprises the establishment of an objective parameter that will be measured in respective units of the articles and acceptable conditions of the objective parameter and the capture of a digitized complete visual image of a unit of the articles being manufactured. The digitized visual image represents pixels and combinations of pixels in the visual image. The method analyzes the digital representations of the pixel combinations in at least the first area and the second area of the captured digitized complete visual image, these respective areas of the image are specified to indicate, together or in combination, an acceptable condition common of the objective parameter. Therefore the method generates the first replication determination signal and the second respective replication determination signal representative of the target parameter and analyzes the determination signals in combination, for compliance with the established acceptable conditions, using one or more methods of respective adequate analyzes for each analysis.

In some embodiments, the method includes the analysis of the representations of the pixel combinations in at least the first area and the second area of the image and therefore the generation of the first combination determination signal and the second signal of determining the respective combination, at least for the first parameter and the second parameter.

In some embodiments, the method includes the processing of the determination signals to use the different first analytical method and the second different analytical method to analyze the determination signals representative of the respective first parameter and the second parameter.

In some embodiments, the method includes analyzing the representations of the pixel combinations with at least the respective separate and distinct first, second and third replicates of the condition determinations of the target parameter in at least the first, second and third respective area of the image, optionally at least for the first parameter and the second parameter in respective replication sites in the articles.

The method can include the processing of the respective first and second parameter determination signals, to use the different first analytical method and the second different analytical method to analyze the determination signals representative of the respective first parameter and the second parameter.

The processing of the determination signals can comprise, for example, the calculation of an average of the three signals, the determination of the number of common or nearly common magnitude signals and / or the calculation of the standard deviation based on the determination signals. .

The processing of the determination signals may comprise the conclusion that one of the determination signals is erroneous or otherwise inadequate, has changed in time or intensity, or otherwise changed, of the corresponding signals received from previous units and the modification, correction, or compensation of the combination of signals in order to better use the data thus collected.

The processing of the determination signals may comprise the comparison of the combination of signals with a database of combinations of known and / or expected signals, optionally including a historical probability of the occurrence of some of the combinations and based on the comparison, the development of a conclusion as to the possible cause of some anomaly in the combination of signals and the development of a corresponding response to the combination of signals.

The method may include transmitting the response as a control signal to a process controller that controls the manufacturing operation.

The multiple analyzes of the pixel pattern representations may comprise multiple respective determinations using software interpretation of selected areas of the complete digitized visual image.

The method may include, when the analysis detects an indeterminate or otherwise inadequate enof one of the selected areas of the image, the automatic adjustment of the analysis to a base using a smaller area in the analysis.

The preferred method comprises the analysis of some of the sequential absorbent articles produced in the manufacturing line, preferably all articles produced in the manufacturing line.

In another family of embodiments, the invention comprises a method for measuring the location of an element in an absorbent article that is made in a manufacturing operation. The method comprises establishing an acceptable location for the element in the absorbent article and capturing a digitized total visual image of the absorbent article. The complete digitized visual image represents pixels and combinations of pixels in the visual image. The method analyzes the digital representations of pixel combinations in at least the first and second areas of the captured digitally captured complete image, these respective areas of the image conveniently indicate, together and in combination, a common acceptable place of the element . The element thereby generates the first replication determination signal and the second respective replication determination signals representative of the element location and analyzes the determination signals in combination, for compliance of the place of the element with the established acceptable places, using one or more suitable analysis methods for each analysis.

The method can include the analysis of the representations of pixel combinations in at least the first and second area of the image and thereby the generation of the first combination determination signal and the respective second combination determination signal, for at least the place of the aforementioned element and for a second parameter.

In some embodiments, the method includes the processing of the determination signals to use the different first analytical method and the second different analytical method to analyze the determination signals representative of the respective location and the second parameter.

Preferably, the method includes the analysis of the representations of pixel combinations with at least the respective first, second and third separate and distinct replica of the determination of the place of the element in at least the first, second and third respective area of the image and optionally a second parameter in respective replication sites in the articles.

The method may include the processing of the respective location determination signals and the second parameter, to use the different first analytical method and the second different analytical method to analyze the determination signals representative of the respective location and the second parameter.

The analytical methods may comprise, for example and without limitation, the calculation of an average of the three signals, the determination of the number of common or nearly common magnitude signals and / or the calculation of a standard deviation based on the determination signals.

When the processing of the determination signals comprises the conclusion that one of the determination signals is inadequate, the method can also include the modification of the combination of signals in order to compensate for the inadequate signal.

The method may include the comparison of the combination of signals with a combination database of known and / or expected signals, the optional inclusion of a historical probability of the occurrence of some of the respective combinations in the absorbent articles and based on the comparison, the development of a conclusion as to the possible cause of some anomaly in the combination of signals and the development of a corresponding response to the combination of signals.

The method may include transmitting the response as a control signal to a process controller that controls the manufacturing operation.

The method can include, when the analysis detects the inadequate entry of one of the previous areas of the image, the automatic adjustment of the analysis of an analysis base of a smaller area.

The aforementioned multiple analyzes of the representations of pixel combinations generally comprise multiple respective determinations made using software interpretation of selected areas of the entire digitized visual image.

The invention further comprises a method for determining a characteristic of a parameter of articles that are processed in a manufacturing operation. The method comprises the operation of a system for reproducing visual images that collects visual images in the manufacturing operation and thereby collects discrete visual images in real time at a rate of at least 50 images per minute; sending data representing complete visualized images of the visual images in real time thus collected, to a memory storage device; recovering one or more of these stored digitized visual images from the memory storage device; and detecting an objective parameter in the scanned complete visual image retrieved with at least the first separate and distinct replica and the second replica separate and distinct from the determinations of a condition of a segment of the items.

The invention comprises that the sending of data to the memory storage device and the recovery of the memory storage device comprise the sending of data to a permanent memory storage device and the recovery of the data of said device which conserves the data in memory when the energy is removed from the memory storage device.

In some embodiments, the method comprises the retrieval of off-line historical images, which represent product units that are no longer being routinely and actively processed by the manufacturing operation. The method therefore comprises the analysis of one or more historical sets of images using one or more analytical methods and thereby detecting a trend of change in the manufacturing operation.

The method may include maintaining substantially complete digital integrity of the visual images thus stored, compared to the images collected, to thereby allow substantially complete visual reproduction of the visual images thus stored.

In some embodiments, as with online analysis, the off-line image analysis method includes detection of the target parameter, in respective images, with at least the first separate and distinct replica and the respective separate and distinct second replica. of the determinations at least for the first parameter and the second parameter in respective replication sites in the images.

The method can include detection of the target parameter with at least the first separate and distinct replica and the respective second and distinct replica of the condition determinations of a segment of the items comprising the use of at least one of the following (i) multiple independent determiners, or (ii) a common determiner taking multiple determinations at corresponding sites in the image, or in multiple related recovered images, the sites conveniently indicating, in combination, a common acceptable condition of the target parameter.

BRIEF DESCRIPTION OF THE DRAWINGS FIGURE 1 is a side elevational view of the apparatus for manufacturing absorbent articles of the invention, having an automatic inspection and control system that includes a subsystem of reproduction of visual images comprising the apparatus and controls for collection, visualization and storage of images, as well as the interconnection of the visual image reproduction system with the control system of the manufacturing process and a memory storage system.

FIGURE 2 is a representative and elevational view, also substantially schematic, of a part of a line of manufacturing machines of FIGURE 1, used to make absorbent articles.

FIGURE 3 is a plan view illustrating a typical image as shown to the operator and stored in memory and showing an elongated top view of a part of the manufacturing operation of absorbent articles.

FIGURE 4 is a representative top view and a block diagram of a pair of images captured by an inspection and control system of the invention and illustrating the use of multiple automated measurements of data in a visual image reproduction system.

The invention is not limited in its application to the details of the 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 ways. Also, it should be understood that the terminology and phraseology employed herein are for purposes of description and illustration and should not be considered as limiting. Like reference numbers are used to indicate similar components.

DESCRIPTION OF ILLUSTRATED REALIZATIONS With reference to the drawings and more particularly to FIGURE 2, the numeral 10 designates a pair of side structure elements defining a longitudinally extending processing path for the processing of absorbent articles according to the invention. In the side structures 10 there are two processing driven rollers 12 rotatably mounted by gears 16. The processing drive rollers 12 can be seen towards the left side of FIGURE 1.

Now referring to FIGURE 1, the apparatus for producing absorbent articles of the invention is schematically illustrated at number 18. starting at the left end of FIGURE 1, an underlying frame 20, for example a screen weft impermeable to the moisture, is shown being advanced to the right along the longitudinally extending path, by the drag rollers 12. The upper confining frame, as a weft of the body side lining, is omitted for clarity of representation .

The absorbent pads 24 placed in the weft 20 are shown in spaced intervals generally corresponding to the respective separate and distinct work pieces or products that are converted into absorbent articles along the processing path. Additional elements such as leg cuffs, restraining wings, hip bands and the like are placed, positioned and otherwise consolidated into or within the continuous frame 20, or on or within each other, at various work stations as along the processing path, in the manufacturing process of the absorbent articles.

For example, the winding 26 supplies the material for leg cuffs 28 which is placed on the frame 20 on the rollers 30. Similarly, the winding 32 supplies the material for hip bands 34 which is placed on the frame 20 in 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 placed downstream of the rollers 36. once they are turned on and as long as they remain on , the cameras 38, 40 continuously collect images and transmit them to the display system 49. The image activation device 41 is between the rollers 30 and the camera 38. The image activation device 42 is between the rollers 36 and the camera. 40. The cameras 38, 40 communicate with the display system 49 of the image reproduction system 48.

The image reproduction system 48 includes the display system 49, temporary memory 98, and the permanent memory 100. The display system 49 includes the frame taker 46, the structure buffer 51, and the image analyzer 50. activation of images 41 and 42 are activated by the detection, for example, of the passage of a specific element in each work piece, for example, an outwardly extending ear 44, illustrated in FIGURE 3. This activation provides a signal to the display system 49, which sends detection signals to the frame taker 46 and the respective strobe lamp 57A or 57B, also for each workpiece. In this way, the detection signal synchronizes the activation of the respective strobe lamp and the corresponding socket of the respective structure or image of each respective work piece, being then picked up by and transmitted from the respective chamber, by the frame taker 46.

Each structure thus taken is transmitted by the frame taker 46 to the transient storage of data 51 in the register with movement of the respective work pieces in the manufacturing line in such a way that the frame taker transfers a visual image of each piece of material. work in accordance with the detection signals created by the passage of the respective work pieces by the image activation devices 41 and 42. While the image activation devices 41 and 42 are illustrated between the respective rollers and chambers, the activation devices could be anywhere in the processing line which is compatible with the timely collection of structures that are registered by the respective camera or cameras.

In this way, a visual image of each work piece is taken and analyzed by the visualization system 49. These visual images are sent from the frame taker 46 to the transient storage of data 51, from there to the image analyzer 50 where it is made the data analysis and, at the request of the activation event signal 102, to the temporary memory 98. After being processed by the display system 49, the processed signal per camera is sent to the video image display device 52 The frame taker, the transient data storage, the image analyzer, the temporary memory and the permanent memory are all elements of the image reproduction system 48 in the embodiment illustrated.

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

Referring now to FIGURE 1, a suitable image reproduction system for use in the invention, including camera, video image display device, frame taker and image analyzer, is available from Cognex Corporation, Natic, Massachusetts, United States of America, such as CHECKPOINT 800. The software suitable for collecting, displaying and analyzing the visual images thus collected, of some individual absorbent articles that are elaborated in the manufacturing operation, is also available by Cognex Corporation.

The visual image signals collected by the camera 38 and the optional camera 40 are processed by the frame taker 46 and image analyzer 50. The frame taker 46 converts the images received from the camera or cameras into digitized representations of the visual images well registered. The image analyzer 50 analyzes the digitized representations, making a series of measurements according to the instructions of the software programmed at the beginning. The results of these analyzes are supplied to the process control 54. The process control 54 receives these results and issues output commands, as appropriate, to adjust and modify the manufacturing process in order to rectify any irregular reading and, as appropriate, 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 of the manufacturing line, or to advance or delay the synchronization, of one or more of the process steps in the respective work stations in the processing line . In addition, signals can be sent to select product from the manufacturing line and / or stop the line.

Referring again to FIGURE 1, the number 56 designates a main transmission motor which drives the machinery that operates the production line of absorbent articles, the main transmission motor being used to rotate a line axis 58 coupled by the gearbox 60, 62, to the drive rollers or rotating rollers 64, 66 respectively.

The line shaft 58 is also coupled by the gearbox 68 to the differential 70 which is driven by the motor 72 in response to the process control signals 54 through a forward signaling device 74 or a signaling device. inverted 76, both are coupled to the motor 72, to advance or delay the driving speed of the rollers 36 and thereby advance or delay the flow velocity of the workpieces through the rollers 36 and, consequently, the positioning relative in which the web material 34 is applied to the work pieces.

In the same way, the line axis 58 is coupled by the gearbox 78 to the differential 80 which is driven by the motor 82 in response to the process control signals 54 through signaling devices 74, 76, both of which are also coupled to the motor 82, to advance or delay the relative positioning of the work pieces through the rollers 30 and, consequently, the relative positioning in which the material of the leg cuffs 28 is applied to the work pieces .

In addition, the line shaft 58 is coupled by the gearbox 84 to the differential 86 which is driven by the motor 88 in response to the process control signals 54 through 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 to the rollers 12 and, consequently, the speed at which the frame 20 and the elements residing therein are supplied to the current work stations down respectively. After an image has been analyzed by the analyzer 50 and has been processed by the process control 54, the correction logic representing the range of acceptable specifications for the work piece can be provided to the signaling devices 74 (forward ) and / or 76 (inverted), or vacuum control 94 to select the work pieces.

The additional work stations, not shown, can be used in a similar way to place and / or fix other elements of the absorbent articles, directly or indirectly, in the frame 20.

The vacuum skate 90 is placed on 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 that was reproduced and analyzed is outside the accepted range of specifications, the process control 54 sends a selection signal 96 to the vacuum control 94, activating the vacuum to the vacuum skate 90 at the appropriate time to select the individual workpiece that the who provided the information that is out of specifications. When desired and when the suitable delivery time is available for the selection system, the vacuum control 94 can be programmed to select, in addition, a specified number of work pieces before and / or after the workpiece which produced the information of visual images that are outside the specifications.

In addition to providing an outlet for process control 54, the display system 49, upon request, also provides visual image information to the high-speed temporary memory 98 which subsequently provides the visual image information to the permanent memory 100. The visual image information introduced from the visualization system 49 to the temporary memory 98 and subsequently to the permanent memory 100, it is sufficient in quantity and satisfactory in quality and specificity, to re-create generally the individual images collected by the camera 38 and / or camera 40. In this way, the stored information substantially the total integrity, in general the total digital integrity, of the visual images thus stored, to be fully representative of the images recorded or collected by the camera 38 or 40. Consequently, the visual images thus stored allow the user to reproduce substantially the respective images which were They were available to the operator in real time during the manufacture of the respective absorbent articles.

A suitable temporary memory for general use in succession to the invention is a VME memory card having memory capacity of up to 1 Gigabyte and is available from Chrislin Industries Inc .. estlake Village, California, United States of America. This temporary memory can capture and store in memory visual images of typical absorbent articles such as those described herein, at high capture / storage s of at least 500 images per minute, up to 1000 images per minute, potentially up to 1200 images. per minute.

The communication between the display system 49 and the temporary memory device 98 requires the use of a suitable protocol such as a VME standard for transferring data through the backplate of the computer or other link to a temporary memory device. This temporary memory is an IEEE 1014 standard VME bus.

While the high rate of image capture of the temporary memory 98 is important for the prolonged capture and storage of digitized complete visual images, the memory storage devices of high capture rate have certain limitations. First of all, these devices are costly in terms of the cost per image thus captured and stored. In addition, high capture rate devices such as the buffering devices described above are temporary memory storage devices within the context that these storage devices retain information captured in memory only if the respective memory device is activated and they lose all the information stored in the memory when the energy is removed from these memory devices.

Accordingly, in order to effect permanent storage, it is critical that the visual image information received in the high-s temporary memory storage device, for example buffer, be immediately transferred to a permanent memory storage device. A suitable and typical permanent memory storage device is such as, for example, a hard drive like the hard drives commonly used in personal computers. When a larger amount of memory is desired than is available in a conventionally available hard disk drive, a combination of these hard disk drives can be coupled in a known manner to thereby provide the composite capacity of all the hard disk drives as well. coupled.

The value of the temporary memory device 98 is to allow high-s real-time transfer of the visual image information of the image reproduction system. Conventional permanent memory devices are too slow for real-time transfer at any reasonable interconnection cost, which is why the temporary memory device is used.

The value of the permanent memory 100 is triple.

First, once the information has been received in the permanent memory, this permanent memory can be accessed by a variety of users, if desired, through a typical networked computer interconnection system. Secondly, permanent memory retains the information in the memory when the power is turned off and where the power is disconnected from the permanent memory storage device and the energy is then lost. In this way, once the visual image information is placed in the permanent memory, the risk of loss by suppression or interruption of the power supply is obvious. Third, the permanent memory is less expensive than the temporary memory, for example, the buffer.

Consequently, images that have conventionally been available only to the operator in the manufacturing line and that have been available only as real-time images, are now available at any time, for anyone who has access to the permanent memory device, such as from a remote computing terminal to, and remote from, the network access 106. Similarly, automatic analysis data made by the image analyzer 50 and stored in the process control 54 can be obtained and accessed from a remote terminal, such as a personal computer, to the network access 106, thus allowing direct correlation and comparison of specific images with the specific information of the process control. The images, therefore, remain available for real-time use in the manufacturing line, as before; and may, in addition, be accessed either inside or outside the manufacturing floor at a later time by an authorized user, for further analysis at any level of analysis desired.

In this way, the visual images of the product, or the process, can be archived and permanently associated with specific manufacturing periods or specific manufacturing events, without interrupting the ongoing collection of these visual images. In addition, the visual images thus stored in the memory can be created again from the data stored in the same system or other visualization system, or they can be stored and reused in other software applications as well as in combination with bitmap systems. However stored and recovered, the recovered information can be used for detailed analysis of the results, in the work pieces, of specific events that occur in the manufacturing line, as well as the analysis of the products made in the manufacturing line.

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

As is well known from the use of these computer memory devices, the visual image data that is permanently stored in, for example, the permanent storage device 100 can be written or erased on a voluntary basis in order to make available this storage space to store other information, for example, the latest data produced.

The above-described image reproduction system 48 has a nominal capacity capable of producing a visual image of each and every one of the work pieces produced by the manufacturing operation at speeds of up to 1200 images per minute. In fact, it is convenient for the line operator that the image reproduction system produces a visual image of each and every one of the pieces of work and permanently records certain data pertaining to each and every one of the pieces of work. However, the routine measurement data recorded by the image reproduction system conventionally comprises only the result information related to the visual image, for example, certain distance measurements and has no ability to recreate the actual image.

It is not practical to store a complete visual image, pixel by pixel, of each and every one of the work pieces. Storage of all the visual images thus produced would require an exorbitant amount of memory storage capacity. Further, since the rate of production of these images is greater than the input rate capability of a permanent memory storage device with typical hard disk drive to receive such information, storage would have to be performed in parallel with multiple devices in memory permanently concurrently receiving memory storage entries. In addition, the amount of data thus stored in the memory would make it difficult for a person making a query to identify images of particular interest for further study and / or the correlation of these images with specific events in the manufacturing process. In this way, the efficient search, classification and retrieval of visual image information suggests at least an initial classification of these images before storage to store only those images that have a relatively higher probability of containing information that will be valuable during the analysis. of subsequent data.

Accordingly, it is important that the digitized complete visual images are transferred from transient data storage 51 to a memory storage device as the temporary buffer 98 only when selected activation events occur., preferably predetermined. By limiting transfers to memory to only those images associated with certain activation events or other higher-risk events, the amount of storage media required is adequately limited to a manageable amount and the amount of data stored and that can be reviewed to find evidence of an event of interest, it is also limited to be manageable.

The suggested image reproduction system Cognex can be programmed to transfer to the memory a specified number of visual images when a specified activation event occurs. The transfer may begin to take samples where the work piece that is reproduced when the activation occurred 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, as an activation event for data collection of visual images, an event of interest which can be identified for process control and captured by the camera. For example, a splice in some of the power frames 20, 28, 34 could be specified as an activation event. A certain amount of change in line speed could be specified as an activation event. A certain amount of change in the tension of one or more frames could be specified as an activation event. A condition that is out of specification could be specified as an activation event. In addition, a manual activation can be used to start capturing images, such as a stopwatch, for a random number generator.

Although the activation event is created or triggered, the manufacturing controls are configured in such a way that, when an activation event occurs, a signal 102 is generated, for example, by a sensor or by a process control command and transmitted to the display system 49, activating the transient data storage 51 to begin sending visual images to the memory and specifying how many images should be sent to the memory.

In this way, when an activation event occurs to identify the first image of a group of images to be retained, a defined set of a limited number of real-time visual images thus collected is sent from the transient data storage 51 to the device. of temporary memory 98. Preferably, while information is still being received by the temporary memory device 98, the memory device 98 begins to transfer the visual image information to the permanent memory device 100 at the slowest rate at which the permanent memory device is capable of receiving and storing said information.

Accordingly, in the preferred embodiments, part of the visual image information has already been transferred to the permanent storage device 100 for the time in which the last of the images was received in the high-speed memory 98. Accordingly, the memory device 98 acts as an accumulator to temporarily take the surplus volume of the visual images that are transferred from the display system 49, until the memory device 100 can receive the rest of the images.

In case a second activation event occurs before the last images of the first set have been transferred to the memory device 100, the temporary memory device 98 receives the second set of images and transfers the second set of images to the recording device. memory 100 after optionally concurrent with, the completion of the transfer of the first set of images.

In some embodiments, the first set and the second set of visual images are segregated from each other, as a separate and distinct set 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 an activation event, preferably, no more visual images are transferred to the memory devices 98, 100 until the next activation event occurs. While a few visual images can be routinely transferred to the storage memory during the routine operation of the process, for record keeping purposes, for example, to maintain a historical record of products made and / or sent, or for, for example, detailed off-line routine evaluation, for example, by an operator, the number of images collected in sequence for each sample is considerably smaller, especially less than 10 percent, preferably less than 2 percent, as well as the number of images which are stored in accordance with the occurrence of a typical activation event.

A typical set of images includes images of 1 to 1000 consecutive work pieces in the processing line. A range of 1 to 200 work pieces is contemplated for typical use in the invention. Storing much less than the low number of work pieces mentioned loses the evidence of the activation event. Storing more than the high number of work pieces mentioned will excessively increase storage costs, notwithstanding computer memory, and can create such a large database that finding useful information can be difficult, or at least inefficient. The larger sets of work piece images can, of course, be stored if the requirements in the resources are justified by the particular situation.

The illustrated embodiments indicate the use of one or two cameras 38, 40. normally, the use of a camera is suitable to indicate the strengths or weaknesses of the manufacturing operation. However, when there is an anomaly, or it is difficult to correct, or when, for example, for some reason more information is desired, additional cameras, such as camera 40, can be installed in the same places or additional places corresponding along the the manufacturing line and connect to the image reproduction system 48 and the memory system (device 98 and device 100), in order to collect and permanently store additional information. Accordingly, the image reproduction system can reproduce and store a second set of data in memory, either before, for example, shortly before, during, or after, for example, shortly thereafter, to collect and store a first set of data. of data. The second data set can be obtained from the same camera, for example, directed to the same place in the processing line, as the first data set or can be obtained from a second camera directed in the same direction in the processing line or located in a different work station, registering a different step in the process.

By associating the appropriate identification signs with each transfer of a set of visual images with storage, the person performing the review can first look for identification signs and having found the identification signs, can then focus on the parameters of interest associated with the identification. the respective visual images.

When it is desired to correlate specific physical samples with the visual images of these samples, a specific article code, different for each piece of work thus coded, can be printed on the respective work pieces 25, as, for example, on the ear 44. This code can be marked, for example, printed, by a non-contact ink jet printer 104 located upstream of the respective chamber such that the code appears both in the physical product, and in the visual image of that unit. product. In the alternative, the specific product unit can be segregated and the operator can manually dial the unit with the code. As a further alternative, a common code, specific to the activation event, may be printed on each work piece, associated with the activation event.

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

Generally, the invention has been described in terms of known or planned activation events. However, the image reproduction system 48 can be programmed to activate the storage of visual images in memory when a wide variety of unplanned events occur, for example, some occurrence of an event outside of the specifications, or some other event not planned, as well as routine sampling.

In some embodiments, the activation signals collect visual images of very few work pieces that are processed in the manufacturing operation. When desired, the image reproduction system can be programmed to collect images of each second workpiece, each third workpiece, or some other desired fraction of the workpieces. This selection can collect images at regular intervals, or at selected intermittent intervals. For example, the image reproduction system could be programmed to order the taking of images of a set / number of consecutive work pieces, for example three work pieces, then omit the next set of work pieces, for example five pieces of work. The actual interval between the work pieces whose images are recorded and the pattern from which the images of the work pieces are to be collected, is a matter of selecting the person who adjusts the collection of images.

As used herein, "absorbent article" refers to a class of products used in the body and generally used for the promotion of human hygiene by absorption of body fluids and other exudates. Examples of these absorbent articles include, without limitation, diapers, trainers, incontinence diapers, feminine pads, interlabial pads and the like.

As used herein, a "high-speed" memory storage device is a storage device capable of receiving at least 50, preferably at least 200, and more preferably at least 300, in a manner still more preferable at least 400 or 500, up to at least 1200, visual images per minute of cameras of the nature described herein for use in the invention and should be able to probe the unit rate of manufacturing products of interest to the image reproduction system. These commonly available memory devices are known as random access memory devices and / or buffer devices, both terms being well known in the art. These normally available memory storage devices retain data only if energy is maintained in those devices and where all data stored therein is lost when the electrical power is suppressed. Consequently, these memory devices are not suitable for permanent data storage. Rather, in the invention, the data 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 whose images must be collected.

As used herein, a "lower speed" memory storage device is a memory storage device which is unable to receive visual images of absorbent articles from the transient data storage 51 of the nature described herein. for use in the invention, generally at a rate of less than 500 visual images per minute. Typical memory devices are hard drives, such as those commonly used in personal computers. These hard drives are available in a variety of sizes and in a range of input rates, where large amounts of image data can easily be stored in permanent memory, at a reasonable cost per image, albeit at input rates more low.

The number of images that can be transferred during 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 and / or the higher the image resolution, the slower the transfer rate capability of the display system 49.

As used herein, reference to a "generally fixed" place where the visual images are collected means that the image collection element, such as a camera, is fixedly installed to a physical support and is directed to a step or specific steps in a specific workstation in the manufacturing operation. In this way, "generally fixed" refers to a fixed camera in its place but with the ability to digitally or optically approach the image to facilitate the inspection of certain elements of the piece or pieces of work, without moving to the same time the camera of its installation place. The cameras can, of course, move and subsequently recalibrate.

Preferably, the camera is fixed both in place and in the direction of the object, in such a way that the consecutively collected images represent the common place and the common direction of the object of the camera.

As used herein, "image pattern" refers to an ongoing selection of images according to a selection pattern. The selection pattern can select and, therefore, collect a specific image for each piece of work, product, or process condition. The selection pattern can alternatively select and pick up an image according to an alternative pattern, for example collecting an image of every second or third work piece, product, or process condition, or collecting an image of each piece of work, product, or process condition for a limited number of images, at regularly spaced intervals, or otherwise determined. The patterns previously written are exemplary only and are not limiting, since other patterns are now obvious and feasible in the invention.

Referring now to FIGURE 4, the image analyzer 50 includes the processor 108 and the controller 110. The processor 108 analyzes the respective images according to the software instructions received from the controller 110. These software instructions are generally input to the controller 110 by an operator of the image reproduction system 48. The image reproduction system 48, the video screen 52 and the process control 54 are all elements of the general inspection and control system indicated as 112.

The images recorded by the display system 49 are recorded as images in pixels. In this way, the combination of the activities of the respective pixels completes the respective image. Consequently, any useful digitized data is useful only to the extent that the data can be converted from pixel to another form which is subject to interpretation by one of the five human senses. And the knowledge of the pixel activity that represents the information of interest transmits the knowledge pertaining to the condition of the product represented by the image. One of the functions of the processor 108 is to interrogate the respective digitized images with respect to the activities of the respective pixels, whether recognized or not, or pixel groups in an image.

Normally, each pixel has a wide range of signal magnitudes, for example 256 possible magnitudes. Consequently, a pixel that does not register an element of interest can, however, register a lower level noise signal. Therefore, the control system is programmed to recognize only those pixels that have a signal strength above the specified minimum. The minimum specified in this way serves as an electronic filter to filter out most noise signals. The magnitude of the threshold, of course, has a relationship with the ability of the controller to discriminate between the noise signals and the actual detection signals, whereby the historical data is normally used as a basis for reaching the level of detection of the most convenient threshold of pixel activity.

While the storage or analysis of a fully digitized visual complete image requires a substantial commitment of analysis and storage resources, the storage and / or analysis of only certain areas of the image requires much less commitment of calculation and / or storage capacity . In this way, one can analyze only those areas of the image which are known to have a higher than average risk of failure and can store only the results of those analyzes.

In this way, the energies directed towards the improvement of process control can focus on those elements of the product or process that offer the greatest opportunity for improvement. Since the larger opportunities are associated with a relatively low fraction of the area of an absorbent article, one can analyze all the highest opportunity areas, of each product unit, store the results and limit the commitment of calculation resources and storage capacity to something much less than that which would be required for analysis and / or storage of a fully digitized image of each product unit.

For example, one may choose to detect the presence and measure the location of a running band 34 of a disposable diaper 25. The process for detecting the presence and measuring the location of the hip band, or some other element, comprises the analysis of the digital image in places where the respective hip element / band is expected to be found. This analysis comprises the analysis of a group of pixels in the respective place, the determination of each pixel if it is recognized or not and therefore the determination of the presence and the place of the hip band. The image analyzer 50 includes the ability to do these analyzes whereby the condition of the product unit can be ascertained automatically by reviewing the test results collected and collected by the image analyzer 50.

The conventional practice is to automatically analyze a group of pixels for each element of, for example, diaper to be detected and / or found.

Thus, according to conventional practice, the processor 108 can analyze a first group of pixels to determine the presence and location of the hip band, a second group of pixels to determine the presence and location of an ear 44 , a third group of pixels to determine the presence and location of the absorbent core 24 and the like.

Inventors in the present have discovered that the difficulty with these analyzes is that the automatic determination may be in error, or may be subject to doubt. In this case, a researcher has no recourse to resolve the doubt, or to determine the error, unless the image is saved. However, as discussed previously in the present, it is impossible to store and store digital complete images of all product units. Rather, just select groups of images, if any, and store them in the format of complete digital images. As a result, conventional analytical methods do not provide a mechanism for the researcher to resolve errors or doubts as to the true condition of the product.

When taking only one reading from, for example, a group of pixels arranged in a linear fashion along a line where the element is expected to be present, the reading is only good up to the point where the area analyzed is a representation precise of the integrity of the presence, if any, of the element in the product. And when a reading of only a part of the element is taken, there is a risk that the reading of the area is not representative of the integrity of the element being evaluated, in which case an erroneous conclusion will be reached.

For example, in FIGURE 4, in the diaper 25B, the portions 111 of the hip band 34 are folded adjacent to the right edge 113 of the diaper, while fully extending adequately toward the left edge. 114 of the diaper. Accordingly, a single reading of the hip band as a band of pixels extending in the machine direction where the hip band should be placed may provide an erroneous reading depending on where the reading is taken in the diaper width. If the reading is taken adjacent to the right edge 113, the problem will be detected. However, if the reading is taken anywhere to the left of the defective area of the hip band, the problem will not be detected.

In this way, if the analysis is made in the group of pixels 118A adjacent to the right side of the diaper, the problem is properly detected. If the analysis is made in group of pixels 118B, further to the left of the right side, the problem may or may not be detected. If the analysis is done in group of pixels 118C or 118D, the analysis will not detect the problem and the product can be released as acceptable since the existing defect was not detected.

To overcome this conventional operation defect, the invention performs duplicative analyzes of one or more groups of pixels of interest at spaced locations in the product unit, in order to detect and correct defective analyzes. Therefore, in FIGURE 4, the processes of the invention analyze at least two groups of piexels in the execution of any given data request.

For example, pixel scans can be taken in two or more groups of pixels 118A, 118B, 118C, 118D, or more.

When at least two groups of pixels are analyzed with respect to some data request, the invention provides improved prospects for detecting real anomalies in the product. The larger the number of groups of pixels analyzed by a given data request, the greater the probability that increasingly sophisticated analytical tools can detect groups of irregular pixels and thereby provide a really accurate data report.

Referring again to FIGURE 4, when all 4 groups of pixels, 118A, 118B, 118C, 118D are ascertained / analyzed by the image analyzer 50, analysis of at least the group of pixels 118A will produce the irregular data , by means of which the defect will be detected with precision. Once the defect has been detected, the operator can be alerted to make a manual inspection, confirm if the product is actually defective and then correct the product and / or the inspection system, discover the cause of the defective signal.

In contrast, if only one group of pixels is used and only one resulting measurement is made in a place where a defective product unit appears acceptable, the inspection and control system would automatically conclude that the product was acceptable and the product would be erroneously released to shipment .

Therefore, upon detecting an irregular data condition, the system 112 issues a signal that directs the manual inspection of the associated product units, to determine if the respective element is actually present and in the correct position. If desired, the inspection and control system 112 may also segregate the associated product until such time as the operator makes the determination whether the product is actually acceptable or defective.

Given the duplicative results of the replica pixel groups, where the results of the respective pixel group are in agreement with each other, the operator can have a high degree of confidence that the analysis is an accurate reflection of the actual condition of the product unit and can act confidently on that basis. While the operator could choose to manually inspect the respective product units, manual inspection would have a relatively lower priority due to reliance on duplicative analytical results.

The illustrated image production system 48 can, on a progressive and continuous basis, be simultaneously evaluating, processing and responding to a variety of parameters conditions of the articles that are manufactured. Primarily, the image analyzer 50 can receive image signals for an ongoing number of item units that are manufactured by the production apparatus 18.

In the invention, when the analyzer 50 receives the various images, the pixel groups of the images are analyzed for compliance with the expected parameters. When a group of pixels indicates that the product unit is outside the specification, the system then looks for a group of confirmation pixels of one or more replicate measurements that measure the same parameter of the same item unit in a spaced location. If the measurement is confirmed, the item unit in general is automatically selected. For example, the dryer band 34 is bent over the right side of the work piece 25B almost halfway along the width of the work piece. If only one analysis is taken in, for example, group 118D pixels, an inadequate "acceptance" signal would be sent to process control 54. If only 118A analysis is used, there would be no detection at all of the Hip band 114. Using four analyzes 118A-118D, the actual condition of the hip band 114 is better recorded.

Depending on the number of units thus selected automatically, the operator may or may not be alerted to the selection action. Mainly, if a selection is an isolated incident, in general the operator has to be alerted. However, if a number of units are being selected, or if a high fraction of the items are being selected, then the operator is alerted. The actual condition of the threshold according to which the operator is alerted, is a matter of selection and is programmed into one or more of the image analyzer 50 or process control 54.

When three or more analyzes are performed to determine a single parameter and when one or more irregular readings of an analysis are received, analytical methods can be used to logically determine which readings have the highest probabilities of representing the actual condition of the unit of items and In some circumstances, it may be used to determine the source of the reading or irregular readings.

The controller 110 and / or the processor 108 and / or process control 54 including programmable devices, such as personal computers. One or more of the controller 110 and / or the processor 108 and / or the process control 54 is programmed with the instructions for the handling of irregular signals according to the types of anomalies. For example, when the irregular analysis is only slightly different from the remaining analysis readings, the respective analysis can represent a condition that is out of calibration and the respective computer can automatically recalibrate the respective analysis tool.

Furthermore, when an analysis indicates a total absence of the respective elements and the remaining analyzes provide strong signals indicating the presence of the element and in view of other facts in the situation, the computer can be instructed to conclude that the irregular reading is actually an error and can compile and statistically use the analyzes on the basis of a minor analysis, while alerting the operator to investigate the situation and, optionally, save the respective images in the permanent memory for further analysis.

In some cases, the particular element of interest may be difficult to detect by the image reproduction system and therefore the analyzes, by which analytical tools may need frequent calibration in order to be adequately sensitized to read the respective element. When a particular analysis does not repeatedly transmit any detection signal, or a weak detection signal, the system can automatically recalibrate the analytical tool to improve the ability to detect the element of interest.

For example, in some cases, after the upper frame, either the body side lining or the screen, has been placed on the absorbent core, the absorbent core can be difficult to detect, depending on the sensitivity of the image reproduction system that is used to detect the absorbent core. In such a case, the calibration of the camera and / or the image reproduction system may be critical for the correct detection of the absorbent core. In some cases where the image or camera playback system requires frequent calibration, the computer can program this out-of-calibration condition and automatically recalibrate the device or otherwise recalibrate while maintaining the normal operation of the inspections, such as so that what was the irregular analysis provides the same signal response to the equivalent input as the remaining analyzes. This situation is of automatic calibration, of course, they require periodic manual consignment that the automatic calibrations are in fact causing the analyzes to detect the actual conditions of the articles in the manufacturing line.

In accordance with the illustrated embodiments, replication analyzes typically take the replicas of a fully digitized common analyzer 50 from a product unit in a single workstation on the manufacturing line, preferably at uniformly spaced locations along the the respective dimension of the element, in such a way that the replication sites can represent in the best possible way the actual condition of the element, whereby the reliability of the conditions of the automatic inspection and control system 112 must be improved.

On the other hand, when sufficiently accurate registration is available, a replication reading of an individual parameter may be taken at a subsequent work station downstream of the workstation where the first reading was taken. However, concerns regarding the accuracy of registration generally preclude the taking of replicate readings on separate workstations. In general, the closer in time and the more evenly spaced the readings of a given parameter are in a given unit of items, the more reliable the replica readings will be.

When two or more parameters are being evaluated by the inspection and control system, the respective computer or computers may use different analytical methods, statistical methods, non-statistical methods, or a combination of statistical and non-statistical methods, to analyze and evaluate the signals different received from the respective analyzes that measure the respective different parameters. In some cases, the analytical method of choice is to average the analyzes. In other cases, the analytical method of choice is to determine the number of readings of common or nearly common magnitude and use only those readings for the rest of the analysis of that unit of articles. However, in other cases, the analytical method of choice is to calculate a standard deviation and proceed on the basis of whether or not the deviation standard indicates a defective product.

In some cases, the analytical method includes the comparison of the combination of readings (the signals from the different readings) with a database of combinations of known and / or expected readings, optionally the inclusion of a historical probability of the occurrence of some of the respective combinations and based on the comparison, the development of a conclusion as to the possible cause of some irregular condition in the analyzes and the development of a response corresponding to the combination of analysis.

Whatever the conclusion of the inspection and control system with respect to an irregular signal, and generating the conclusion is generated by the controller 54 or finally transmitted to the controller 54; and appropriate responses from the controller 54 are transmitted as control commands to the processing machinery, such as transmission units, power units, steering units, positioning units, intake units and the like.

In the alternative, both here and in all the previous analytical methods, confusing logical theories and / or other alternative decision theories can be used to reach conclusions as to the possible cause of an anomaly in the signal combination and to develop a response corresponding and can be used in combination with each other, as well as with more conventional statistical analytical methods.

As with any manufacturing operation, the higher the fraction of the articles that are actually inspected, the greater the reliability of the results of these inspections. In the same way, the larger the number of parameters inspected, the greater the reliability of the results of these inspections. Furthermore, the larger the number of readings or analyzes for a given parameter, the greater the probability that the analyzes can be relied upon to arrive at precise conclusions as to the conditions of the parameters that are due.

Accordingly, the invention contemplates taking a number of readings, preferably at least three readings, for each parameter that will be measured for each unit of articles that are manufactured and taking these readings for a number of typical parameters of the number of parameters read for the manufacture of these articles. Of course, there is a practical limit to the number of parameters that can be read and the number of readings and the amount of calculation capacity and memory of the computer, which can be applied to data collection, data analysis and the development of conclusions. of them and the storage of the data and the conclusions thus compiled and developed. As a result, sound decisions must be made regarding how much information will actually be collected, analyzed and stored for subsequent manual review and evaluation.

A main advantage of the invention is that the inadequate determination signals of a single analysis do not cause the inspection and control system to incorrectly accept or reject defective products or to deactivate the system of the control functions. On the contrary, based on the replication determination signals, in some cases, the control system can automatically correct this analytical tool. In other cases, the control system can determine that the error signal is in fact an error of the analytical tool. In other cases, the control system can alert the operator of a group of high risk products and suggest manual inspection and save the respective images in the permanent memory for further evaluation. In general, the invention provides a control system that more accurately determines the actual condition of the articles and better identifies the series or batches of articles for manual verification and / or inspection, the batches representing a relatively higher risk of having relatively higher fractions of defective items.

As used herein, "programmable device" includes, but is not limited to, a user-programmable computer, a computer that accepts programmed interchangeable chips or other inputs to a computer or control system, scheduled interchangeable computer processors, or interchangeable computer processing boards.

Those skilled in the art will see that certain modifications to the apparatus and methods disclosed herein can be made with respect to the illustrated embodiments, without departing from the spirit of the invention. And while the invention has been described with respect to the foregoing embodiments, it will be understood that the invention is adapted to numerous changes, modifications and alterations and all these changes, modifications and alterations are intended to be within the scope of the appended claims.

To the extent that the following claims use the meanings plus the function language, anything not structurally equivalent to what is shown in the embodiments disclosed in the specification should not be included there, or in the immediate specification.

Claims (71)

R E I V I N D I C A C I O N S

1. A method for measuring a parameter of items that are made in a manufacturing operation, the method comprising: (a) the establishment of an objective parameter that will be measured in the articles and the acceptable conditions of the objective parameter. (b) the development of a measurement strategy to measure the objective parameter; (c) detection of the target parameter with respect to at least the first separate separate replica and the respective separate and distinct second replica of the condition determinations of a segment of the articles and thereby the development of at least the first separate and distinct replication determination signal and the second separate and distinct replication determination signal respectively as representations of the respective parameter; (d) after the development of the measurement strategy, the programming of a programmable device to use an adequate method of analysis in order to evaluate the determination signals; (e) the transmission of the determination signals to the programmable device for analysis; Y (f) processing the determination signals in the programmable device to use the respective analysis method in order to analyze the determination signals thus received.

2. A method as claimed in clause 1, characterized in that the detection of the target parameter with at least the first separate and distinct replica and the respective second and separate replicates of the determinations for at least the first parameter and the second parameter of the respective replication sites in the articles.

3. A method as claimed in clause 2, characterized in that the processing of the determination signals to use the first different analytical method and the second different analytical method in order to analyze the determination signals representative of the first parameter and the second respective parameter.

4. A method as claimed in clause 1, characterized in that the detection of the target parameter is at least the respective first, second and third separate and distinct replica of the condition determinations of the articles.

5. A method as claimed in clause 1, characterized in that the detection of the target parameter is at least the respective first, second and third separate and distinct replicates of the determinations, each for at least the first parameter and the second parameter in the respective replication sites in the articles.

6. A method as claimed in clause 5, characterized in that the processing of the respective first parameter and the second parameter determination signals for using the different first analytical method and the respective different analytical method in order to analyze the signals of representative determination of the first respective parameter and the second parameter.

7. A method as claimed in clause 1, characterized in that the detection of the target parameter using the first separate and distinct sensor and the second separate and distinct sensor.

8. A method as claimed in clause 1, characterized in that the detection of the target parameter using the first separate and distinct sensor and the second separate and separate sensor selected from the group consisting of photoelectric sensors, infrared sensors, sensors of movement, temperature sensors, cameras and light sensors.

9. A method as claimed in clause 4, characterized in that the processing of the determination signals comprising the calculation of an average of the signals.

10. A method as claimed in clause 4, characterized in that the processing of the determination signals comprising the determination of the number of signals of common or almost common signal characteristics.

11. A method as claimed in clause 4, characterized in that the processing of the determination signals comprises the calculation of a standard deviation based on the determination signals.

12. A method as claimed in clause 1, characterized in that when the analysis of the determination signals comprises the conclusion that one of the determination signals is incorrect or has changed improperly, the method includes modification, correction, or compensation, of the combination of signals to better use the data thus collected.

13. A method as claimed in clause 1, characterized in that the comparison of the combination of signals a database of combinations of known and / or expected signals and based on the comparison, the development of a conclusion as to the possible cause of some anomaly in the combination of signals and the development of a response corresponding to the combination of signals.

14. A method as claimed in clause 1, characterized in that the comparison of the combination of signals a database of combinations of known and / or expected signals, the inclusion of a historical probability of the occurrence of some of the combinations respective and based on the comparison, the development of a conclusion as to the possible cause of some anomaly in the combination of signals and the development of a response corresponding to the combination of signals.

15. A method as claimed in clause 13, characterized in that the transmission of the response as a control signal to a process controller that controls the manufacturing operation.

16. A method as claimed in clause 4, characterized in that when the analysis detects an "out of calibration" condition in one of the multiple independent determiners, automatic recalibration of the "out of calibration" determiner is included.

17. A method as claimed in clause 4, characterized in that when the analysis detects the inadequate input of one of the multiple independent determiners, automatic adjustment of the analysis is included to a base of a minor determiner.

18. A method as claimed in clause 17, characterized in that the automatic implementation of the back-up inspection of the articles associated the inadequate input of the determiner.

19. A method as claimed in clause 1, characterized in that the manufacturing operation comprises a manufacturing line having a plurality of work stations and where the first replica and the second replica are taken in a common work station.

20. A method as claimed in clause 1, characterized in that the manufacturing operation comprises a manufacturing line having a plurality of work stations and where the second replica is taken at a workstation downstream from the workstation. work where the first replica is taken.

21. A method as claimed in clause 1, characterized in that the manufacturing operation elaborating units of articles, the method further comprising the analysis of each unit of the articles.

22. A method as claimed in clause 1, characterized in that the detection of the target parameter at least the first separate and distinct replica and the respective second and separate replicates of the condition determinations of a segment of the articles comprising the use of at least one of the following: (i) multiple independent determiners, or (ii) a common determiner taking multiple determinations at corresponding sites in the article, these sites conveniently indicating, in combination, a common acceptable condition of the objective parameter.

23. A method for measuring a parameter of articles that are made in a manufacturing operation, the method comprising: (a) establishing an objective parameter that will be measured in the respective units of the articles and the acceptable conditions of the objective parameter; (b) capturing a complete digitized visual image of a unit of the articles that are manufactured, the digitized visual image representing pixels and combination of pixels in the visual image; (c) in the captured complete digital visual image, the analysis of the digital representations of pixel combinations in at least the first area and the second area of the image, the respective areas of the image are specified to indicate, together or in combination, a common acceptable condition of the target parameter and thereby the generation of the first replication determination signal and the second replication determination signal representative of the target parameter; Y (d) the analysis of the determination signals in combination, for compliance of the established objective parameter with the acceptable conditions established using the respective adequate analysis methods.

24. A method as claimed in clause 23, characterized in that the analysis of the representations of pixel combinations in at least the first area and the second area of the image and thereby the generation of the first combination determination signal and the second respective combination determination signal, for at least the first parameter and the second parameter.

25. A method as claimed in clause 23, characterized in that the processing of the determination signals to use the first different analytical method and the second different analytical method in order to analyze the determination signals representative of the first parameter and the second respective parameter.

26. A method as claimed in clause 23, characterized in that the analysis of the representations of pixel combinations with at least the first, second and third respective separate and distinct replicates of the condition determinations of the target parameter in at least, the first, second and third respective areas of the image.

27. A method as claimed in clause 23, characterized in that the analysis of the representations of pixel combinations in at least the first, second and third respective areas of the image for at least the first parameter and the second parameter in respective replica sites in the articles.

28. A method as claimed in clause 27, characterized in that the processing of the determination signals of the first parameter and the second respective parameter to use the first different analytical method and the second different analytical method in order to analyze the signals of representative determination of the respective first parameter and the second parameter.

29. A method as claimed in clause 26, characterized in that the processing of the determination signals comprises calculating an average of the signals.

30. A method as claimed in clause 23, characterized in that the processing of the determination signals comprising the determination of the number of signals of common or near-common signal characteristics.

31. A method as claimed in clause 26, characterized in that the processing of the determination signals comprises the calculation of a standard deviation based on the determination signals.

32. A method as claimed in clause 23, characterized in that the processing of the determination signals comprises the conclusion that one of the determination signals is inadequate and the modification of signals to compensate for the inadequate signal.

33. A method as claimed in clause 23, characterized in that the comparison of the combination of signals with a database of combinations of known and / or expected signals and based on the comparison, the development of a conclusion as to the possible cause of some anomaly in the combination of signals and the development of a response corresponding to the combination of signals.

34. A method as claimed in clause 23, characterized in that the comparison of the combination of signals with a database of combinations of known and / or expected signals, the inclusion of a historical probability of the occurrence of some of the combinations respective and based on the comparison, the development of a conclusion as to the possible cause of some anomaly in the combination of signals and the development of a response corresponding to the combination of signals.

35. A method as claimed in clause 33, characterized in that the transmission of the response as a control signal to a process controller that controls the manufacturing operation.

36. A method as claimed in clause 23, characterized in that the multiple analysis of the representations of pixel combinations comprising multiple respective determinations using the software interpretation of selected areas of the complete digitized visual image.

37. A method as claimed in clause 26, characterized in that when the analysis detects the inadequate entry of one of the selected areas of the image, the automatic adjustment of the analysis is included to an analysis basis of a smaller area.

38. A method as claimed in clause 23, characterized in that the method further comprising the analysis of each of the absorbent articles made in the manufacturing line.

39. A method for measuring the place of an item in an absorbent article that is made in a manufacturing operation, the method comprising: (a) establishing an acceptable place for the item in the absorbent article; (b) capturing a complete digitized visual image of the absorbent article, the complete visual image digitized by representing pixels and combinations of pixels in the visual image. (c) in the captured complete digital visual image, the analysis of the digital representations of the pixel combinations in at least the first area and the second area of the image, the respective areas of the image are specified to indicate, as a whole and in combination, a common acceptable place of the element and thereby the generation of the first replication determination signal and the respective second replication signal representative of the place of the element in the product; Y (d) the analysis of the determination and combination signals, for compliance of the place of the element with the established acceptable sites using respective adequate analysis methods.

40. A method as claimed in clause 39, characterized in that the analysis of the representations of pixel combinations in at least the first area and the second area of the image and thereby the generation of the first combination determination signal and the second respective combination determination signal, for at least the location of the aforementioned element and for a second parameter.

41. A method as claimed in clause 40, characterized in that the processing of the determination signals to use the first different analytical method and the second different analytical method in order to analyze the determination signals representative of the respective location and the second parameter.

42. A method as claimed in clause 39, characterized in that the analysis of the representations of pixel combinations with the respective first, second and third separate and distinct replicas of the location determinations of the element in at least the first, second and third respective areas of the image.

43. A method as claimed in clause 39, characterized in that the analysis of the combination representations of pixels in at least the first, second and third respective areas of the image for at least the aforementioned place a second parameter, in respective replica sites in the articles.

44. A method as claimed in clause 43, characterized in that the processing of the respective location determination signals and the second parameter, in order to use the first different analytical method and the second different analytical method to analyze the signals of determination representative of the respective place and the second parameter.

45. A method as claimed in clause 42, characterized in that the processing of the determination signals comprises calculating an average of the signals.

46. A method as claimed in clause 39, characterized in that the processing of the determination signals comprising the determination of the number of signals of common or near-common signal characteristics.

47. A method as claimed in clause 39, characterized in that the processing of the determination signals comprises the calculation of a standard deviation based on the determination signals.

48. A method as claimed in clause 39, characterized in that when the processing of the determination signals comprises the conclusion that one of the determination signals is inadequate, the method further includes modifying the combination of signals to compensate with it the inadequate signal.

49. A method as claimed in clause 39, characterized in that the comparison of the combination of signals with a database of combinations of known and / or expected signals and based on the comparison, the development of a conclusion as to the possible cause of some anomaly in the combination of signals and the development of a response corresponding to the combination of signals.

50. A method as claimed in clause 39, characterized in that the comparison of the combination of signals with a database of combinations of known and / or expected signals, the inclusion of a historical probability of the occurrence of some of the combinations respective in the absorbent articles and based on the comparison, the development of a conclusion as to the possible cause of some anomaly in the combination of signals and the development of a response corresponding to the combination of signals.

51. A method as claimed in clause 49, characterized in that the transmission of the response as a control signal to a process controller that controls the manufacturing operation.

52. A method as claimed in clause 39, characterized in that the multiple analysis of the representations of pixel combinations comprising multiple respective determinations using the software interpretation of selected areas of the complete digitized visual image.

53. A method as claimed in clause 42, characterized in that when the analysis detects the inadequate entry of one of the previous areas of the image, the automatic adjustment of the analysis is included to an analysis basis of a smaller area.

54. A method as claimed in clause 39, characterized in that the method further comprising the analysis of each of the absorbent articles made in the manufacturing line.

55. A method for determining a characteristic of a parameter of articles that are elaborated in a manufacturing operation, of the method comprising: (a) the operation of a visual image reproduction system that collects visual images in the manufacturing operation and thereby collects discrete visual images in real time at a rate of at least 50 images per minute; (b) sending data representing complete digitized visual images of the real-time visual images thus collected, to a memory storage device; (c) recovering one or more of the stored digitized visual complete images from the memory storage device; Y (d) the detection of an objective parameter in the recovered digitized complete visual image, with at least the first and second separate and distinct replicates of the determinations of a condition of a segment of the articles.

56. A method as claimed in clause 55, characterized in that the data is sent to the memory storage device and the recovery of the memory storage device, including the sending of data to a permanent memory storage device and the recovery of the data of said device which retains the data in the memory when the energy of the memory storage device is suppressed.

57. A method as claimed in clause 55, characterized in that the detection of the target parameter comprising the use of at least one of the multiple independent determiners or a common determiner taking multiple determinations at corresponding sites in the article which indicate convenient way, in combination, a common acceptable condition of the objective parameter.

58. A method as claimed in clause 55, characterized in that the recovery of the stored digitized visual complete images of the memory storage device comprising the retrieval of off-line historical images, which represent product units that are no longer worked Routinely and actively by the manufacturing operation.

59. A method as claimed in clause 58, comprising the analysis of one or more historical series of images using one or more analytical methods and thereby detecting a trend of change in the manufacturing operation.

60. A method as claimed in clause 55, characterized in that substantially maintaining the digital integrity of the visual images thus stored, as compared to the images collected, to thereby allow substantially complete visual reproduction of the visual images as well stored.

61. A method as claimed in clause 55, characterized in that the detection of the target parameter, in the respective images, with at least the first separate and distinct replica and the respective second and separate replicates of the determinations for minus the first parameter and the second parameter in respective replication sites in the images.

62. A method as claimed in clause 61, characterized in that the processing of the determination signals to use the first different analytical method and the second different analytical method in order to analyze the determination signals representative of the first parameter and the second respective parameter.

63. A method as claimed in clause 55, characterized in that the detection of the target parameter with at least the first, second and third respective separate and distinct replicates of the condition determinations of the articles.

64. A method as claimed in clause 62, characterized in that the processing of the determination signals comprises the calculation of an average of the signals.

65. A method as claimed in clause 62, characterized in that the processing of the determination signals comprising the determination of the number of signals of common or near-common signal characteristics.

66. A method as claimed in clause 62, characterized in that the processing of the determination signals comprises the calculation of a standard deviation based on the determination signals.

67. A method as claimed in clause 62, characterized in that the comparison of the combination of signals with a database of combinations of known and / or expected signals and based on the comparison, the development of a conclusion as to the possible cause of some anomaly in the combination of signals and the development of a response corresponding to the combination of signals.

68. A method as claimed in clause 57, characterized in that the comparison of the combination of signals with a database of combinations of known and / or expected signals, the inclusion of a historical probability of the occurrence of some of the combinations respective and based on the comparison, the development of a conclusion as to the possible cause of some anomaly in the combination of signals and the development of a response corresponding to the combination of signals.

69. A method as claimed in clause 57, characterized in that when the analysis detects a condition "out of calibration" in one of the multiple independent determiners, automatic recalibration of the "out of calibration" determiner is included.

70. A method as claimed in clause 55, characterized in that the detection of the target parameter with at least the first and second respective separate and distinct replicates of the condition determinations of a segment of the items comprising the use of at least one of the following: (i) multiple independent determiners, or (ii) a common determiner taking multiple determinations at corresponding sites in the image which conveniently indicate, in combination, a common acceptable condition of the target parameter.

71. A method as claimed in clause 55, characterized in that the detection of the target parameter with at least the first and second respective separate and distinct replicates of the condition determinations of a segment of the items comprising the use of at least one of the following: (i) multiple independent determiners, or (ii) a common determiner taking multiple determinations at corresponding sites that the multiple related recovered images of the respective series of images, which conveniently indicate, in combination, a common acceptable condition of the objective parameter. SUMMARY Control processes comprising the detection and measurement of a parameter, for example the presence and location of an item of an item, with at least two determinations as representations of the target parameter, the transmission of signals to the computer and the signal processing to compare the parameter with the acceptable conditions. The detection may include three or more replicas, optionally each for at least two parameters, optionally using at least two different methods to analyze the signals. The invention contemplates the detection and analysis of the target parameters using two or more analytical tools within the respective image to detect a particular component of the product, especially two or more measurements of the parameter in a single visual image. Analytical methods may include the averaging of the signals, the determination of the number of signals of common duration of signals and / or characteristics of signals, the calculation of the standard deviation, the modification of the combination of signals to compensate for an inadequate signal and / or the comparison of the signals with a database of combinations of signals. The method can automatically calculate the possible cause of some irregularities in the signals, develop corresponding responses and transmit responses to the control of the process and there to the control devices. The methods can automatically recalibrate the determiners, or automatically adjust the analysis to a lower determiner base and / or automatically implement the item backup inspection, optionally saving the images for further analysis, or selecting product units. The digitized visual images represent pixels and combinations of pixels. The method contemplates the analysis of the pixel representations with at least two determinations of the parameter in at least two respective areas of the image, optionally for at least two parameters in respective replication sites, using the software interpretation of the areas selected from the visual image.