Absorbent article manufacturing device, absorbent article manufacturing method, and program

Abstract

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

Description

[Technical Field]

[0001] The present invention relates to an apparatus for manufacturing an absorbent article, a method for manufacturing an absorbent article, and a program. [Background technology]

[0002] Conventionally, in manufacturing equipment for producing absorbent articles, a technology is known in which product data and equipment data are associated with each other, and when an abnormality occurs in a product, at least one of the product data and equipment data associated with the product determined to be abnormal is identified, and further the manufacturing process that caused the abnormality in the product is identified. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Publication No. 2018-129030 Summary of the Invention [Problem to be solved by the invention]

[0004] However, the above-mentioned techniques have room for further improvement in terms of early identification of defects in upstream processes in the manufacture of absorbent articles.

[0005] For example, in the above-mentioned technology, an abnormality is detected by a sensor provided downstream of the process of manufacturing the absorbent body in the absorbent article. Therefore, even if there is a problem in the manufacturing state of the absorbent body itself, there is a possibility that another factor causing the abnormality may be added in the process leading up to the sensor, making it difficult to directly identify the problem in the manufacturing state of the absorbent body.

[0006] The present application has been made in view of the above, and aims to identify defects in the upstream processes in the manufacture of absorbent articles at an early stage. [Means for solving the problem]

[0007] The absorbent article manufacturing device of the present application is characterized by comprising: a stacking unit that stacks the absorbent body of the absorbent article from pulverized and / or defibrated material; a first acquisition unit that acquires first information that is information about the manufacture of the absorbent article from at least a sensor provided in the stacking unit; a second acquisition unit that acquires second information that is information about the product of the absorbent article in the absorbent article manufacturing line; a memory unit that stores the first information and the second information in association with each other; a judgment unit that judges whether or not there is an abnormality in at least the stacking unit based on the first information and the second information; and an output unit that outputs the judgment result by the judgment unit. [Effects of the Invention]

[0008] According to one aspect of the embodiment, defects in the upstream process of manufacturing absorbent articles can be identified early. [Brief explanation of the drawings]

[0009] [Figure 1] FIG. 1 is a schematic side view showing an example of the configuration of a production line according to an embodiment. [Figure 2] FIG. 2 is a schematic diagram of diapers produced on a production line. [Figure 3] FIG. 3 is a schematic front view showing an example of the configuration of a laminated section according to the embodiment. [Figure 4] FIG. 4 is a schematic side view showing an example of the configuration of the stacking unit according to the embodiment. [Figure 5] FIG. 5 is an explanatory diagram of the sensor position in the laminated portion according to the embodiment. [Figure 6] FIG. 6 is an explanatory diagram of the flow of intake air in the stacked portion according to the embodiment. [Figure 7] FIG. 7 is a diagram showing an example of the arrangement of plates forming recesses. [Figure 8] FIG. 8 is a schematic plan view of the plate. [Figure 9] FIG. 9 is a diagram showing an example of an image captured at a downstream position of the stacking unit. [Figure 10]FIG. 10 is a block diagram illustrating an example of the configuration of a manufacturing system according to an embodiment. [Figure 11] FIG. 11 is a block diagram illustrating an example of the configuration of a monitoring device according to an embodiment. [Figure 12] FIG. 12 is a diagram illustrating an example of sensor information stored in the acquired information DB. [Figure 13] FIG. 13 is a diagram showing an example of plate information stored in the acquired information DB. [Figure 14] FIG. 14 is a diagram illustrating an example of product information stored in the acquired information DB. [Figure 15] FIG. 15 is an explanatory diagram of an example of linking manufacturing information and product information. [Figure 16] FIG. 16 is a diagram (part 1) showing a specific example of the analysis process. [Figure 17] FIG. 17 is a diagram (part 2) showing a specific example of the analysis process. [Figure 18] FIG. 18 is a diagram (part 3) showing a specific example of the analysis process. [Figure 19] FIG. 19 is a flowchart illustrating a processing procedure executed by the monitoring device according to the embodiment. [Figure 20] FIG. 20 is a diagram illustrating an example of a hardware configuration. DETAILED DESCRIPTION OF THE INVENTION

[0010] At least the following matters will become clear from the description of this specification and the accompanying drawings.

[0011] An absorbent article manufacturing apparatus comprising: a stacking unit that stacks absorbents in the absorbent article from crushed and / or defibrated material; a first acquisition unit that acquires first information that is information about the manufacture of the absorbent article from a sensor provided at least in the stacking unit; a second acquisition unit that acquires second information that is information about the product of the absorbent article in the absorbent article manufacturing line; a memory unit that stores the first information and the second information in association with each other; a judgment unit that judges whether or not there is an abnormality in at least the stacking unit based on the first information and the second information; and an output unit that outputs the judgment result made by the judgment unit.

[0012] According to such an absorbent article manufacturing device, defects in the upstream processes in the manufacture of absorbent articles can be identified early on.

[0013] The stacking unit is also equipped with a rotating drum that has a rotating part that is provided in an annular shape and can rotate around the central axis of the ring, with a plurality of recesses or continuous recesses formed along the outer peripheral surface of the rotating part, a suction part that is provided opposite the inner peripheral surface and the outer peripheral surface of the rotating part, and an intake fan that uses an intake air flow through a pipe that is connected to the suction part at the rear of the rotating drum to suck the material into the recesses to stack the absorber and to remove the stacked absorber from the recesses, and a plurality of the sensors are provided on the pipe.

[0014] According to such an absorbent article manufacturing device, it is possible to obtain high-quality sensor data regarding the intake air flow of the stacked portion that is less susceptible to static electricity and vibration.

[0015] A plurality of pipes are connected to the suction unit, and a plurality of sensors are provided on the straight portions of the respective pipes.

[0016] According to such an absorbent article manufacturing device, stable sensor data can be obtained for each pipe regarding the intake air flow in the stacking section.

[0017] The first information also includes information relating to the pressure and / or flow rate of the intake air flowing through the piping.

[0018] According to such an absorbent article manufacturing device, it is possible to analyze the state of the stacked portion based on the intake air pressure and / or flow rate regarding the intake air flow in the stacked portion, and determine whether or not there is an abnormality in the stacked portion.

[0019] The sensor is at least one of a pressure sensor, a flow rate sensor, and a flow velocity sensor.

[0020] According to this absorbent article manufacturing device, the state of the stacked portion can be analyzed based on the intake air pressure and / or flow rate measured by a pressure sensor and / or flow rate sensor, and it is possible to determine whether or not there is an abnormality in the stacked portion. Furthermore, even if only a pressure sensor is used, the flow rate can be calculated by using Bernoulli's theorem.

[0021] Moreover, the recess is formed by a replaceable plate, and the first information includes information about the plate.

[0022] With this type of absorbent article manufacturing device, it is possible to determine whether or not there is an abnormality on a plate-by-plate basis, and if an abnormality is determined to exist, it is possible to address the abnormality on a plate-by-plate basis.

[0023] The information about the plate includes at least one of information about the identification of the plate, information about the previous maintenance, and information about the next replacement.

[0024] With this type of absorbent article manufacturing device, it is possible to identify plates based on information regarding the plate's identification, and to decide what to do with the identified plates based on information regarding the previous maintenance and information regarding the next replacement.

[0025] The second information also includes information about the finished product and / or semi-finished product.

[0026] According to such an absorbent article manufacturing device, it is possible to analyze the state of the stacked portion based on information on not only the finished product but also the semi-finished product, and to determine whether or not there is an abnormality in the stacked portion.

[0027] The manufacturing line further includes an image sensor provided downstream of the stacking unit, and the second information includes information relating to an image showing a state of the absorber, which is captured by the image sensor.

[0028] With this type of absorbent article manufacturing device, it is possible to detect the distribution of materials in the absorbent body and the stacking state of the absorbent body based on an image showing the state of the absorbent body at a position downstream of the stacking section, analyze the state of the stacking section based on the detection results, and determine whether or not there is an abnormality in the stacking section.

[0029] The material includes at least one of pulp, synthetic fiber, and polymer absorbent material, and the second information includes information about the material.

[0030] According to such an absorbent article manufacturing device, it is possible to analyze the state of the laminated portion based on information about the material of the absorbent body, and determine whether or not there is an abnormality in the laminated portion.

[0031] The device may further include a temperature sensor and / or a humidity sensor, and the first information may include information relating to the temperature measured by the temperature sensor and / or information relating to the humidity measured by the humidity sensor.

[0032] Such an absorbent article manufacturing device can analyze the state of the stacked portion based on information about the ambient environment of the manufacturing line, such as temperature and humidity, and determine whether or not there is an abnormality in the stacked portion.

[0033] An example of a manufacturing apparatus, a manufacturing method, and a program for manufacturing absorbent articles (hereinafter referred to as an "embodiment") will be described in detail below with reference to the drawings. Note that the manufacturing apparatus, the manufacturing method, and the program for manufacturing absorbent articles are not limited to this embodiment. Furthermore, the same parts in the following embodiments are given the same reference numerals, and duplicated explanations will be omitted.

[0034] [Embodiment] [1. Example of manufacturing line configuration] First, an example of the configuration of a production line PL for producing absorbent articles will be described with reference to Figures 1 and 2. Figure 1 is a schematic side view showing an example of the configuration of the production line PL according to an embodiment. Figure 2 is a schematic view of diapers produced in the production line PL. At least a portion of the production line PL is included in a manufacturing apparatus 50 according to an embodiment described below.

[0035] The manufacturing line PL according to the embodiment is a continuous manufacturing process for manufacturing absorbent articles, such as diapers, sanitary napkins, and urine absorption pads. In the following description, the manufacturing of diapers D as an absorbent article will be mainly taken as an example.

[0036] In the production line PL, multiple processing steps are performed at different locations on the continuous sheet (also called the "continuous web"), which is the source of diaper D. Note that "processing" here refers to all the steps that are performed on the continuous web before one piece of diaper D is finally produced.

[0037] Therefore, this includes processes in which traces of the "processing" remain on each piece of diaper D, such as sequentially placing absorbents on a continuous web, forming the continuous web into a predetermined shape, and cutting it into pieces, as well as processes in which no traces of the "processing" remain on each piece of diaper D, such as material splicing processes that connect materials together so that the continuous web or other material is not broken.

[0038] In the following, the width direction of the production line PL (the direction penetrating the paper in Figure 1) will be referred to as the "CD direction", and of the two directions perpendicular to the CD direction, the vertical direction will be referred to as the "up-down direction" and the horizontal direction will be referred to as the "front-to-back direction".

[0039] As shown in Figure 1, the manufacturing line PL includes a core wrap conveying path R1, an absorbent conveying path R2, a fastening tape conveying path R3, a top sheet conveying path R4, a target tape conveying path R5, a back sheet conveying path R6, and a base sheet conveying path R7.

[0040] Each of the transport routes R1 to R7 is provided with a transport device (not shown). The transport device is composed of a belt conveyor, transport rollers, etc. The belt conveyor may be, for example, a normal belt conveyor with a drivingly rotating endless belt as the transport surface, or a suction belt conveyor with a suction function on the outer circumferential surface of the endless belt.

[0041] In the core wrap conveying path R1, the core wrap sheet Cs is unwound from a material coil 201 in which the core wrap sheet Cs is wound into a coil shape. That is, in the core wrap conveying path R1, the core wrap sheet Cs, which is a continuous sheet, is conveyed. The core wrap sheet Cs is a liquid-permeable sheet material such as tissue paper or nonwoven fabric.

[0042] In the absorber transport path R2, the absorber Ab is placed on the core wrap sheet Cs transported from the core wrap transport path R1. The absorber Ab is a liquid absorber material, and is, for example, a laminated body made by mixing and laminating pulp fiber and superabsorbent polymer (SAP).

[0043] The absorbent body Ab is laminated in a laminating section 100 provided in the production line PL. The laminating section 100 has a pulverizer 101, a spreader 102, a rotating drum 103, and a hood Fd. The pulverizer 101 uses a rotary blade to pulp and / or defibrate a pulp material Pw drawn from a pulp roll (not shown) to generate pulp fibers, which are then carried by an air current and sent into the hood Fd.

[0044] The spreader 102 spreads SAP into the hood Fd at a predetermined interval. One end of the hood Fd is connected to the crusher 101, while the other end is connected to the rotating drum 103 so as to cover part of the outer circumferential surface of the rotating drum 103. The pulp fibers and SAP sent into the hood Fd are mixed by the multiphase flow generated within the hood Fd.

[0045] The rotary drum 103 rotates around a rotation axis along the CD direction, and layers the pulp fibers and SAP mixed in the hood Fd to form the absorber Ab, which is then placed on the core wrap sheet Cs.

[0046] The rotating drum 103 has a plurality of recesses 103a formed on its outer circumferential surface along the direction of rotation. The recesses 103a are formed so that the absorber Ab placed on the core wrap sheet Cs has a substantially rectangular shape in plan view. The recesses 103a may be provided not only discontinuously and intermittently but also continuously.

[0047] The recess 103a stacks the absorbers Ab against its bottom surface by sucking the pulp fibers and SAP mixed in the hood Fd. As the rotating drum 103 rotates, it removes the absorbers Ab stacked in the recess 103a from the recess 103a and transfers them to the absorber transport path R2, thereby placing the absorbers Ab on the core wrap sheet Cs. As a result, multiple absorbers Ab are placed side by side in the front-to-rear direction on the core wrap sheet Cs.

[0048] The configuration for achieving suction and transfer in the stacking unit 100 will be described later with reference to FIGS. 3 to 8 and the like.

[0049] A press device 202 is provided on the absorbent body transport path R2. The press device 202 includes a pair of press rolls 202a and 202b. The press rolls 202a and 202b each rotate around a rotation axis along the CD direction. The press rolls 202a and 202b sandwich and pressurize the absorbent body Ab passing between them from above and below.

[0050] Furthermore, a cutting device 203 is provided downstream of the pressing device 202. The cutting device 203 cuts the core wrap sheet Cs on which the absorbent body Ab is placed. The cutting device 203 includes a cutter roll 203a and an anvil roll 203b.

[0051] The cutter roll 203a rotates around a rotation axis along the CD direction. The cutter roll 203a is provided with a cutter blade along the rotation axis direction. The anvil roll 203b rotates around a rotation axis along the CD direction.

[0052] The cutting device 203 sandwiches and cuts the core wrap sheet Cs on which the absorbents Ab are placed using a cutter roll 203a and anvil roll 203b. The cutting device 203 cuts the core wrap sheet Cs at a position between adjacent absorbents Ab.

[0053] In the absorber transport path R2, the core wrap sheet Cs cut by the cutting device 203 is transported forward.

[0054] The fastening tape Ft1, which is a continuous sheet, is transported along the fastening tape transport path R3. An adhesive applicator 204 applies adhesive to the fastening tape Ft1 along the fastening tape transport path R3.

[0055] In the top sheet conveying path R4, the top sheet Ts is unwound from a material coil 205 in which the top sheet Ts is wound into a coil shape. That is, in the top sheet conveying path R4, the top sheet Ts, which is a continuous sheet, is conveyed. The top sheet Ts is a liquid-permeable sheet member, and is, for example, a nonwoven fabric containing thermoplastic resin fibers such as polyethylene or polypropylene.

[0056] Additionally, a slip cutter device 206 is provided on the top sheet feed path R4. The slip cutter device 206 cuts the fastening tape Ft1 fed on the fastening tape feed path R3. The slip cutter device 206 includes a cutter roll 206a and an anvil roll 206b.

[0057] The cutter roll 206a rotates around a rotation axis aligned in the CD direction. The cutter roll 206a is provided with cutter blades (not shown) that cut the continuous sheet of fastening tape Ft1 into single sheets of fastening tape Ft2. Multiple cutter blades are provided in the rotation direction.

[0058] The anvil roll 206b suction-holds the continuous fastening tape Ft1 coated with adhesive. The anvil roll 206b rotates around a rotation axis aligned in the CD direction. The anvil roll 206b is provided with a receiving blade (not shown) that faces the cutter blade of the cutter roll 206a.

[0059] The slip cut device 206 sucks the continuous sheet of fastening tape Ft1 coated with adhesive with an anvil roll 206b, and cuts the continuous sheet of fastening tape Ft1 with a cutter roll 206a to generate single sheets of fastening tape Ft2.

[0060] The slip cut device 206 adsorbs the fastening tape Ft2 cut into single sheets by the anvil roll 206b and transports it to a position opposite the top sheet Ts.

[0061] Further, a temporary press roll 207 is provided below the anvil roll 206b on the top sheet transport path R4. The temporary press roll 207 is provided so as to face the anvil roll 206b with the top sheet Ts sandwiched therebetween.

[0062] The temporary press roll 207 rotates around a rotation axis aligned with the CD direction. The temporary press roll 207 presses the fastening tape Ft2, which is attracted to the anvil roll 206b, toward the anvil roll 206b when it is transported above the top sheet Ts. This presses the top sheet Ts, which is a continuous body, against the anvil roll 206b, and the adhesive applied to the fastening tape Ft2 bonds the fastening tape Ft2 to the top sheet Ts. This temporarily fixes the fastening tape Ft2 to the top sheet Ts.

[0063] Further, the top sheet transport path R4 is provided with a main press device 208. The main press device 208 is provided downstream of the temporary press roll 207 in the transport direction of the top sheet Ts on the top sheet transport path R4.

[0064] The final press device 208 finally fixes the fastening tape Ft2 that has been temporarily fixed to the top sheet Ts. The final press device 208 clamps the top sheet Ts, to which the fastening tape Ft2 has been temporarily fixed, between a pair of rolls, and finally fixes the fastening tape Ft2 to the top sheet Ts.

[0065] Each roll rotates around a rotation axis along the CD direction. One roll of a pair of rolls reciprocates toward the other roll. That is, the distance between the pair of rolls can be changed.

[0066] Additionally, an adhesive applicator 209 is provided on the top sheet transport path R4. The adhesive applicator 209 is provided downstream of the main press device 208 in the transport direction of the top sheet Ts. The adhesive applicator 209 applies adhesive to the top sheet Ts to which the fastening tape Ft2 is finally fixed. The adhesive applicator 209 applies adhesive to the non-skin side of the top sheet Ts.

[0067] A target tape Tt1, which is a continuous sheet, is transported along the target tape transport path R5. Along the target tape transport path R5, an adhesive applicator 210 applies adhesive to the target tape Tt1.

[0068] In the backsheet conveying path R6, the backsheet Bs is unwound from a material coil 211 in which the backsheet Bs is wound into a coil shape. That is, in the backsheet conveying path R6, the backsheet Bs, which is a continuous sheet, is conveyed. The backsheet Bs is a liquid-impermeable sheet member, and is, for example, a thermoplastic resin film such as polyethylene.

[0069] Additionally, the back sheet transport path R6 is provided with a slip cutter device 212. The slip cutter device 212 cuts the target tape Tt1 transported along the target tape transport path R5. The slip cutter device 212 includes a cutter roll 212a and an anvil roll 212b.

[0070] The cutter roll 212a rotates around a rotation axis aligned in the CD direction. The cutter roll 212a is provided with cutter blades (not shown) that cut the continuous sheet of target tape Tt1 into single-cut target tapes Tt2. Multiple cutter blades are provided in the rotation direction.

[0071] The anvil roll 212b suction-holds the continuous target tape Tt1 coated with adhesive. The anvil roll 212b rotates around a rotation axis aligned in the CD direction. The anvil roll 212b is provided with a receiving blade (not shown) that faces the cutter blade of the cutter roll 212a.

[0072] The slip cut device 212 sucks the target tape Tt1, which is a continuous sheet coated with adhesive, with an anvil roll 212b, and cuts the target tape Tt1, which is a continuous sheet, with a cutter roll 212a to generate a single piece of target tape Tt2.

[0073] The slip cut device 212 adsorbs the target tape Tt2 cut into a single piece by the anvil roll 212b and transports it to a position facing the back sheet Bs.

[0074] Further, in the back sheet conveying path R6, a temporary press roll 213 is provided below the anvil roll 212b. The temporary press roll 213 is provided so as to face the anvil roll 212b with the back sheet Bs sandwiched therebetween.

[0075] The temporary press roll 213 rotates around a rotation axis aligned with the CD direction. The temporary press roll 213 presses the target tape Tt2, which is attracted to the anvil roll 212b, toward the anvil roll 212b when it is transported above the back sheet Bs. As a result, the back sheet Bs, which is a continuous body, is pressed against the anvil roll 212b, and the target tape Tt2 is adhered to the back sheet Bs by the adhesive applied to the target tape Tt2. As a result, the target tape Tt2 is temporarily fixed to the back sheet Bs.

[0076] Further, the back sheet conveying path R6 is provided with a main press device 214. The main press device 214 is provided downstream of the temporary press roll 213 in the conveying direction of the back sheet Bs on the back sheet conveying path R6.

[0077] The final press device 214 finally fixes the target tape Tt2 that has been temporarily fixed to the back sheet Bs. The final press device 214 clamps the back sheet Bs to which the target tape Tt2 has been temporarily fixed between a pair of rolls, and finally fixes the target tape Tt2 to the back sheet Bs.

[0078] Each roll rotates around a rotation axis along the CD direction. One roll of a pair of rolls reciprocates toward the other roll. That is, the distance between the pair of rolls can be changed.

[0079] An adhesive applicator 215 is also provided on the backsheet conveying path R6. The adhesive applicator 215 is provided downstream of the main press device 214 in the conveying direction of the backsheet Bs. The adhesive applicator 215 applies adhesive to the backsheet Bs to which the target tape Tt2 is finally fixed. The adhesive applicator 215 applies adhesive to the skin side of the backsheet Bs.

[0080] The absorbent Ab transported by the absorbent transport path R2, the top sheet Ts transported by the top sheet transport path R4, and the back sheet Bs transported by the back sheet transport path R6 join at a joining position Mp.

[0081] Specifically, at the joining position Mp, the continuous back sheet Bs joins the non-skin side of the absorbent Ab, and the continuous top sheet Ts joins the skin side of the absorbent Ab. Because the top sheet Ts and back sheet Bs are each coated with adhesive, the top sheet Ts, absorbent Ab, and back sheet Bs are bonded and integrated by the adhesive to form a continuous base sheet BMs. On the base sheet BMs, the absorbents Ab are continuously lined up in the front-to-back direction at a product pitch P corresponding to the length of one piece of diaper D.

[0082] In Figure 1, the base sheet BMs downstream of the junction point Mp in the conveying direction of the base sheet BMs is shown in a state in which the top sheet Ts, absorbent body Ab, and back sheet Bs are separated from each other, but in reality they are joined together.

[0083] The base sheet BMs is conveyed along the base sheet conveying path R7. A leg hole cutting device 216 is provided on the base sheet conveying path R7. The leg hole cutting device 216 cuts a portion of the base sheet BMs on both sides in the CD direction to form leg openings of the diaper D. The leg hole cutting device 216 includes a cutter roll 216a and an anvil roll 216b.

[0084] The cutter roll 216a rotates around a rotation axis that is aligned with the CD direction. A cutter blade (not shown) is provided on the cutter roll 216a along the rotation direction. The cutter blade is provided in a curved shape that matches the shape of the leg openings. The anvil roll 216b rotates around a rotation axis that is aligned with the CD direction.

[0085] The rotation of each of the rolls 216a, 216b in the leg hole cutting device 216 is linked to the conveyance operation of the base sheet BMs so that leg openings are formed at predetermined positions in the base sheet BMs.

[0086] In the leg hole cutting device 216, the cutter roll 216a is movable toward the anvil roll 216b, and the distance between the cutter roll 216a and the anvil roll 216b is changeable.

[0087] Further, the base sheet conveying path R7 is provided with an end cutting device 217. The end cutting device 217 is provided downstream of the leg hole cutting device 216 in the conveying direction of the base sheet BMs on the base sheet conveying path R7.

[0088] The end cutting device 217 cuts the base sheet BMs conveyed along the base sheet conveying path R7, and includes a cutter roll 217a and an anvil roll 217b.

[0089] The cutter roll 217a rotates around a rotation axis along the CD direction. The cutter roll 217a is provided with a cutter blade (not shown) along the rotation axis direction. The anvil roll 217b rotates around a rotation axis along the CD direction.

[0090] The end cutting device 217 cuts the downstream end of the base sheet BMs at a predetermined position on the base sheet BMs to produce the diaper D shown in FIG.

[0091] The circumferential length of the cutter roll 203a is set to the same value as the length of the product pitch P, which is the length of one piece of diaper D shown in Fig. 2. Therefore, when the cutter roll 203a makes one rotation, for example, the absorbent Ab is transported by a transport amount equal to the length of the product pitch P.

[0092] The manufactured diapers D then undergo an inspection process, which may include visual inspection by humans, before being moved to the final shipping process. In addition, some existing technologies, for example, inspect the semi-finished diapers D between each processing step on the production line PL in order to identify defects on the production line PL at an early stage.

[0093] However, as already mentioned, there is room for further improvement in the existing technology in terms of early identification of defects in the upstream processes in the manufacture of diaper D.

[0094] For example, in the existing technology, an abnormality is detected by a sensor provided downstream of the process of manufacturing the absorbent Ab in the diaper D, i.e., the lamination process of the absorbent Ab in the lamination unit 100 shown in Fig. 1. Therefore, even if there is a problem with the manufacturing state of the absorbent Ab itself, for example, the lamination state of the pulp fiber and SAP, there is a possibility that other factors causing the abnormality may be introduced, such as the introduction of foreign matter in the factory, in the process leading up to the sensor, making it difficult to directly identify the problem in the manufacturing state of the absorbent Ab.

[0095] Therefore, in the manufacturing method according to the embodiment, first information relating to the manufacture of diapers D is acquired from at least a sensor provided in the stacking unit 100, second information relating to the manufacture of diapers D on the manufacturing line PL is acquired, and the first information and second information are stored in association with each other. Then, based on the first information and the second information, it is determined whether or not there is an abnormality in at least the stacking unit 100, and the determination result is output.

[0096] An example of the configuration of a manufacturing system 1 to which the manufacturing method according to this embodiment is applied will be described in detail below with reference to FIG. 3 and subsequent figures.

[0097] 2. Example of the configuration of the manufacturing system according to the embodiment [2-1. Example of laminated section configuration] First, a configuration example of the stacked unit 100 according to the embodiment will be described. Fig. 3 is a schematic front view showing the configuration example of the stacked unit 100 according to the embodiment. Fig. 4 is a schematic side view showing the configuration example of the stacked unit 100 according to the embodiment. Fig. 5 is an explanatory diagram of the sensor position in the stacked unit 100 according to the embodiment.

[0098] Fig. 6 is an explanatory diagram of the flow of intake air in the stack unit 100 according to the embodiment. Fig. 7 is a diagram showing an example of the arrangement of plates Pt that form recesses 103a. Fig. 8 is a schematic plan view of the plates Pt. Fig. 9 is a diagram showing an example of an image captured at a downstream position of the stack unit 100.

[0099] 3, the sprayer 102 has a nozzle 102a and a sensor 102b. The nozzle 102a is a spray port for SAP. The sensor 102b detects the pressure or flow rate of the SAP-carrying flow sprayed from the sprayer 102 by air conveyance.

[0100] The rotating drum 103 also has a rotating portion 103b. The rotating portion 103b is provided in an annular shape and rotates around the central axis of the annular shape. The recesses 103a are formed in multiple or continuous fashion along the outer circumferential surface of the rotating portion 103b. The stacked portion 100 also has air intakes 104-A, 104-B, 104-C, 104-D, 104-E, and 104-F. The air intakes 104-A, 104-B, 104-C, 104-D, and 104-E are formed behind the rotating drum 103 and arranged along the inner periphery of the rotating drum 103.

[0101] Air intakes 104-A, 104-B, 104-C, and 104-D are provided at positions corresponding to the upper semicircular region when rotating drum 103 is divided into two halves, one above the other, along the horizontal diameter of rotating drum 103. Air intake 104-E is provided at a position corresponding to the lower semicircular region when rotating drum 103 is similarly divided into two halves.

[0102] The stacking unit 100 further includes a transfer conveyor 105. The transfer conveyor 105 forms the absorber transport path R2 described above. The air intake 104-F is provided below the rotating drum 103, specifically at a position corresponding to the transfer position of the absorber Ab from the rotating drum 103 to the transfer conveyor 105.

[0103] 3, for example, the above-described pressing device 202 further includes a camera 202c. The camera 202c is provided downstream of the pressing device 202 and is capable of capturing images of the absorber Ab in three-dimensional directions. The camera 202c captures, for example, X-ray images of the absorber Ab.

[0104] Here, the camera 202c is an example of an imaging sensor that captures an image showing the state of the absorbent body Ab at a position downstream of the stacking unit 100. Therefore, not only the press device 202 but also the above-mentioned cutting device 203, leg hole cutting device 216, end cutting device 217, etc. may have an imaging sensor equivalent to the camera 202c. Of course, such an imaging sensor may be provided anywhere on the absorbent body conveying path R2 as long as it is located downstream of the stacking unit 100, but it is preferable that it be located at least at a position after the absorbent body Ab has been pressurized.

[0105] The stacking unit 100 also has sensors in the pipes connected to the intake ports 104-A, 104-B, 104-C, 104-D, 104-E, and 104-F. As shown in Fig. 4, the stacking unit 100 has, behind the rotating drum 103, pipes 106, a drive unit 107, and an intake fan 108.

[0106] The pipes 106 are ducts that draw air from the intake ports 104-A, 104-B, 104-C, 104-D, 104-E, and 104-F. To make the drawing easier to see, Fig. 4 only shows the pipes 106-B connected to the intake port 104-B, the pipes 106-E connected to the intake port 104-E, and the pipes 106-F connected to the intake port 104-F. The pipes 106-A, 106-C, and 106-D (see Fig. 5) connected to the intake ports 104-A, 104-C, and 104-D may be considered to be similar to the pipe 106-B.

[0107] The driving unit 107 rotates the rotating unit 103b of the rotary drum 103. The intake fan 108 is a fan to which the pipes 106 are collectively connected, and which forms an intake air flow within each pipe 106.

[0108] The stacked unit 100 includes a plurality of sensors for detecting the state of each intake air flow. The plurality of sensors are arranged in the region P-Sr shown in Fig. 4. The region P-Sr is, for example, a part of the straight portion of each pipe 106.

[0109] 5, for example, three sensors are provided for each region P-Sr of each pipe 106. The sensors are basically pressure sensors. By measuring the pressure of the intake flow, the flow velocity and flow rate can be calculated according to Bernoulli's theorem, but a flow velocity sensor or a flow rate sensor may be provided in addition to or together with the pressure sensors.

[0110] Each pipe 106 has a damper Dp in the region P-Sr. For example, one sensor is disposed on the upstream side of the intake air flow across the damper Dp, and two sensors are disposed on the downstream side of the intake air flow across the damper Dp, and are provided so as to be able to measure at least the total pressure and static pressure in each pipe 106.

[0111] Next, the flow of intake air formed in the stacking unit 100 will be described. As shown in Fig. 6, the rotating drum 103 has spaces A, B, C, D, and E formed in the hollow portion of the rotating unit 103b. The spaces A, B, C, D, and E are substantially closed spaces to which intake ports 104-A, 104-B, 104-C, 104-D, and 104-E are connected, respectively, and communicate with the outside air via the recess 103a described above. The spaces A, B, C, D, and E are, so to speak, suction chambers, and correspond to an example of a suction unit provided opposite the inner circumferential surface of the rotating unit 103b.

[0112] As shown in Fig. 7, the recess 103a is formed by a plate Pt attached along the outer peripheral surface of the rotating part 103b. Here, as shown in Fig. 8, the plate Pt has holes punched using a punching metal or the like in the area corresponding to the bottom surface of the recess 103a, and further has an upper layer formed with a porous layer in which holes having a smaller diameter than the holes in the bottom surface are arranged.

[0113] The plate Pt has a bottom surface with a recess 103a formed thereon, and the plate Pt can be replaced as needed depending on the product being manufactured in the production line PL. The plate Pt can also be replaced as needed due to clogging, deterioration over time, etc.

[0114] Although Figures 7 and 8 show an example in which one plate Pt corresponds to one recess 103a, this does not limit the form of the plate Pt, and multiple recesses 103a may be formed in one plate Pt.

[0115] Returning to the explanation of Figure 6, spaces A, B, C, and D communicate with the outside air inside the hood Fd via the bottom surface of the recess 103a. Space E communicates with the outside air outside the hood Fd via the bottom surface of the recess 103a.

[0116] The stacking unit 100 also has a space F below the transfer position of the absorber Ab on the transfer conveyor 105. The space F is a substantially closed space connected to an air intake 104-F. The space F communicates with the outside air on the upper surface of the absorber Ab on the transfer position side. The space F is a suction chamber, similar to the spaces A, B, C, D, and E, and corresponds to an example of a suction unit provided opposite the outer peripheral surface of the rotating unit 103b.

[0117] In the stacking section 100 configured as described above, when pulp fibers are sent from the grinder 101 into the hood Fd and SAP is sprayed into the hood Fd from the nozzle 102a of the sprayer 102, the pulp fibers and SAP are mixed by the multiphase flow.

[0118] On the other hand, when the intake fans are driven, an intake air flow is formed in each pipe 106, and negative pressure is created in each of spaces A, B, C, D, E, and F. As a result, the intake air flow shown in FIG. 6 is generated in each of spaces A, B, C, D, E, and F.

[0119] In this state, in the example of Figure 6, if the rotating part 103b rotates clockwise, the pulp fibers and SAP in the hood Fd are sucked into and stacked on the bottom surface of one recess 103a as it passes through the positions facing spaces A, B, C, and D.

[0120] Furthermore, while the recess 103a passes a position facing the space E, the stacked absorbent Ab is held in the recess 103a so as not to fall. Then, when the recess 103a passes a position facing the space F, the absorbent Ab is released from the recess 103a by the intake air flow generated in the space F and is transferred to the transfer conveyor 105.

[0121] Furthermore, the above-mentioned camera 202c captures an image of the absorber Ab pressed from above and below in the press device 202. The camera 202c captures, for example, an X-ray image as shown in Fig. 9. By analyzing the image captured by the camera 202c, it becomes possible to detect, for example, the distribution state of pulp fibers and SAP.

[0122] Furthermore, when the absorbent Ab passes between the press rolls 202a and 202b, at least one of the press rolls 202a and 202b of the press device 202 vibrates in accordance with the smoothness of the absorbent Ab. At this time, the press device 202 can measure the runout of the rotation axis of the press roll 202a and / or the press roll 202b during such vibration as a displacement amount (distance) a from a reference plane using a displacement sensor (not shown). By analyzing this displacement amount a, it becomes possible to detect the layering state of, for example, pulp fibers and SAP. The press device 202 may also detect the layering state by measuring the vibration of at least one of the press rolls 202a and 202b using a vibration sensor (not shown) when the absorbent Ab passes through.

[0123] [2-2. Example of manufacturing system configuration] Next, Fig. 10 is a block diagram showing an example of the configuration of a manufacturing system 1 according to an embodiment. In addition to Fig. 10, a block diagram is also shown in Fig. 11, which will be described later. However, these block diagrams show only the components necessary to explain the features of this embodiment, and general components are omitted.

[0124] In other words, the components shown in these block diagrams are functional concepts and do not necessarily have to be physically configured as shown. For example, the specific form of distribution and integration of each block is not limited to that shown, and all or part of them can be functionally or physically distributed and integrated in any unit depending on various loads, usage conditions, etc.

[0125] Furthermore, in the explanations using these block diagrams, the explanation of components that have already been explained may be simplified or omitted.

[0126] As shown in FIG. 10, the manufacturing system 1 according to the embodiment includes a monitoring device 10, a manufacturing management device 20, a manufacturing line PL, and a user terminal 500.

[0127] The monitoring device 10, the manufacturing management device 20, and the manufacturing line PL are communicably connected to each other via a network N-1, which is a wired or wireless communication line. The network N-1 is, for example, an intranet configured by a LAN (Local Area Network) or the like.

[0128] The monitoring device 10 and the user terminal 500 are communicably connected to each other via a network N-2, which is a wired or wireless communication line. The network N-2 is a communication network such as a LAN, a WAN (Wide Area Network), a telephone network (such as a mobile phone network or a landline telephone network), a regional IP (Internet Protocol) network, or the Internet. In the following, when there is no need to particularly distinguish between the networks N-1 and N-2, they will be simply referred to as "network N."

[0129] The monitoring device 10 and at least a part of the production line PL constitute a manufacturing apparatus 50 according to the embodiment. The at least a part of the production line PL referred to here is the stacking unit 100, the various sensors Sr included in the stacking unit 100, and the other various sensors Sr included in the production line PL.

[0130] [2-3. Monitoring Devices] The monitoring device 10 is a device that acquires first information, which is information related to the production of diapers D, from various sensors Sr provided at least in the stacking unit 100, and acquires second information, which is information related to the production of diapers D on the production line PL. The monitoring device 10 also associates the acquired first information and second information and stores them, determines whether or not there is an abnormality in at least the stacking unit 100 based on the first information and the second information, and outputs the determination result.

[0131] The monitoring device 10 has a condition analysis model DB (Database) 13b. The monitoring device 10 uses the condition analysis model DB 13b to analyze the condition of the stack unit 100 based on the first information and the second information, and determines whether or not there is an abnormality in at least the stack unit 100.

[0132] A specific example of an analysis method using the state analysis model DB 13b will be described later with reference to FIGS.

[0133] The monitoring device 10 also outputs the determination result to its own HMI (Human Machine Interface) unit 12 (see FIG. 11). The HMI unit 12 is an interface component for human interaction, and includes output components such as a display and a speaker, and input components such as a keyboard and a touch panel.

[0134] Furthermore, the monitoring device 10 generates control signals for controlling various mechanisms in the production line PL as the determination result and outputs the control signals to the production line PL via the network N-1. The monitoring device 10 also outputs the determination result to the user terminal 500 via the network N-2.

[0135] [2-4. Manufacturing control equipment] The manufacturing management device 20 is a device that manages information related to the diaper D products on the manufacturing line PL. The manufacturing management device 20 is used by a manager or the like who manages the manufacturing line PL. The manufacturing management device 20 has a manufacturing management DB 21. The manufacturing management DB 21 stores various information related to the diaper D products.

[0136] The information about the diaper D product includes, for example, a production schedule for the diaper D and a product number that uniquely identifies each manufactured diaper D. The information about the diaper D product also includes, for example, information about the type and composition of materials used in each product. The materials include at least one of pulp, synthetic fiber, and SAP.

[0137] [2-5. About the production line] The production line PL has a stacking unit 100 and a plurality of processing units 300 other than the stacking unit 100. The plurality of processing units 300 correspond to various processing devices involved in the production of diapers D, such as the material coils 201, 205, and 211, the press device 202, the cutter 203, the adhesive applicators 204, 209, 210, and 215, the slip cut devices 206 and 212, the preliminary press rolls 207 and 213, the main press devices 208 and 214, the leg hole cut device 216, the end cut device 217, and the conveying devices that form the respective conveying paths R1 to R7.

[0138] The stacking unit 100 has various sensors Sr. The various sensors Sr of the stacking unit 100 include the sensor 102b of the spreader 102 described above, a plurality of sensors provided in each pipe 106, and the like. The processing unit 300 also has various sensors Sr. The various sensors Sr of the processing unit 300 include the displacement sensor, vibration sensor, camera 202c, and the like that are provided in the press device 202 described above.

[0139] [2-6. User Devices] The user terminal 500 is an information processing device used by a manager or worker of the production line PL. The user terminal 500 may be, for example, an information processing device such as a mobile phone including a smartphone, a tablet terminal, a desktop PC (Personal Computer), a notebook PC, or a PDA (Personal Digital Assistant). The user terminal 500 may also be a wearable device that is an eyeglass-type or watch-type information processing device.

[0140] [2-7. Example of monitoring device configuration] 11 is a block diagram showing an example of the configuration of a monitoring device 10 according to an embodiment. As shown in FIG. 11, the monitoring device 10 includes a communication unit 11, an HMI unit 12, a storage unit 13, and a control unit 14.

[0141] 10, the various sensors Sr, the manufacturing management device 20, the network N-2, and the various mechanisms Mc of the manufacturing line PL are connected to the monitoring device 10 via the communication unit 11. The various mechanisms Mc are, for example, the dampers Dp of the piping 106 described above.

[0142] The communication unit 11 is realized by, for example, a network adapter. The communication unit 11 executes communication processing between the various sensors Sr, the network N-2, the various mechanisms Mc, and the control unit 14. The HMI unit 12 has already been described, so its description will be omitted here.

[0143] The storage unit 13 is realized by, for example, a semiconductor memory element such as a RAM (Random Access Memory) or a flash memory, or a storage device such as a hard disk or an optical disk. The storage unit 13 may also be realized by, for example, a NAS (Network Attached Storage). In the example of FIG. 11, the storage unit 13 stores an acquired information DB 13a and a state analysis model DB 13b.

[0144] The acquired information DB13a is a database that stores manufacturing information (corresponding to an example of "first information") and product information (corresponding to an example of "second information") acquired by the manufacturing information acquisition unit 14a and the product information acquisition unit 14b described below.

[0145] The state analysis model DB 13b is a database that stores various state analysis models used by the analysis unit 14c, which will be described later.

[0146] Here, various types of information stored in the acquired information DB 13a will be described with reference to Figs. 12 to 15. Fig. 12 is a diagram showing an example of sensor information stored in the acquired information DB 13a. Fig. 13 is a diagram showing an example of plate information stored in the acquired information DB 13a. Fig. 14 is a diagram showing an example of product information stored in the acquired information DB 13a. Fig. 15 is an explanatory diagram showing an example of linking manufacturing information and product information.

[0147] As shown in FIG. 12, the acquired information DB 13a stores, for example, "sensor information." The "sensor information" includes a "sensor ID" item, an "installation location" item, a "data type" item, a "reference value" item, and a "sensor data" item. The "sensor information" corresponds to an example of manufacturing information related to the manufacturing of diapers D. Data stored in each item of the "sensor information" is acquired, for example, from various sensors Sr and the manufacturing management DB 21.

[0148] The "sensor ID" item stores identification information that uniquely identifies each type of sensor Sr. The "installation location" item stores the installation location of each type of sensor Sr. The "data type" item stores the type of sensor data measured by each type of sensor Sr. The "reference value" item stores the reference value of the sensor data for each type of sensor Sr. The "sensor data" item stores the sensor data measured by each type of sensor Sr for the most recent specified period.

[0149] The example of FIG. 12 shows that the sensor with the sensor ID "S-01" is the sensor 102b provided in the sprayer 102, and that the sensor 102b is a flow rate sensor that measures the flow rate of SAP.

[0150] 12 shows that the sensors with sensor IDs "A-01" to "A-03" are sensors installed on pipe A, and that the sensors with sensor IDs "A-01" and "A-02" are pressure sensors. The sensor with sensor ID "A-03" is a flow rate sensor. The "A pipe" refers to pipe 106-A connected to intake port 104-A.

[0151] 12 shows that the sensors with sensor IDs "B-01" to "B-03" are sensors installed on the B pipe, and that the sensors with sensor IDs "B-01" and "B-02" are pressure sensors. The sensor with sensor ID "B-03" is a flow rate sensor. The "B pipe" indicates the pipe 106-B connected to the intake port 104-B.

[0152] 12 shows that the sensor with the sensor ID "X-01" is a displacement sensor provided in the press device 202. The example of FIG. 12 also shows that the sensor with the sensor ID "Y-01" is a camera 202c provided downstream of the press device 202.

[0153] Furthermore, the various sensors Sr may be sensors that acquire sensor data of types other than those exemplified above. For example, the example in Fig. 12 shows that the sensor with sensor ID "T-01" is a temperature sensor arranged in the stack section where the stack section 100 is provided. Also, the example in Fig. 12 shows that the sensor with sensor ID "H-01" is a humidity sensor arranged in the stack section where the stack section 100 is provided.

[0154] The temperature of the laminated unit 100 is thought to affect the specific gravity and bulk of the absorbent Ab, the intake air flow rate, how the scattered material falls, the hydrogen bonding of the absorbent Ab, etc. Similarly, the humidity of the laminated unit 100 is thought to affect the likelihood of static electricity generation, changes in weight balance due to adhesion to the wall surface of the hood Fd, the ease of transfer, the ease of clogging, etc.

[0155] 13, the acquired information DB 13a stores, for example, "plate information," which is information related to the above-mentioned plate Pt. The "plate information" corresponds to an example of manufacturing information related to the manufacturing of the diaper D. The data stored in each item of the "plate information" is acquired, for example, from the manufacturing management DB 21.

[0156] "Plate information" includes a "recess ID" item, a "plate ID" item, a "logical number" item, a "front and rear plates" item, a "use start date" item, a "last maintenance date" item, and a "planned replacement date" item.

[0157] The "recess ID" item stores identification information that uniquely identifies the recess 103a of the rotating drum 103. The "plate ID" item stores identification information that uniquely identifies the plate Pt.

[0158] The "logical number" field stores a logical number that is cyclically assigned to each plate Pt on the production line PL. The "front and rear plate" field stores a plate ID that indicates the front and rear mounting direction of a plate Pt on the outer circumferential surface of the rotating drum 103.

[0159] The "Start Date of Use" field stores the start date of use of the corresponding plate Pt. The "Last Maintenance Date" field stores the date of the last maintenance of the corresponding plate Pt. The "Scheduled Replacement Date" field stores the scheduled replacement date of the corresponding plate Pt.

[0160] 14, the acquired information DB 13a stores, for example, "product information," which is information about the aforementioned product. The "product information" includes a "product number" item, a "manufacturing date and time" item, a "daily SEQ number" item, a "corresponding logical number" item, a "pulp material type" item, and a "SAP moisture content" item. The "product information" corresponds to an example of product information about the product diaper D. Data stored in each item of the "product information" is acquired, for example, from the production management DB 21.

[0161] The "product number" field stores identification information that uniquely identifies diaper D. The "manufacturing date and time" field stores the manufacturing date and time when each diaper D was manufactured. The "daily sequence number" is, for example, a number included as part of the manufacturing number, and stores a sequential number assigned to each diaper D for each daily operation of the manufacturing line PL.

[0162] The "corresponding logical number" item stores the logical number (see FIG. 13) corresponding to the first product number of the day, for example, when the production line PL starts operating on the day.

[0163] As shown in Fig. 15, the logical numbers of the plates Pt are cyclically assigned to each plate Pt. Note that the example of Fig. 15 shows a case where the rotary drum 103 is provided with eight recesses 103a.

[0164] On the other hand, the daily SEQ numbers are assigned sequentially over time. As shown in Figure 14, for example, by linking the logical number corresponding to the first product number of the day, if a defective diaper D is found, it is possible to determine the logical number corresponding to the diaper D. This also makes it possible to identify the plate Pt corresponding to the logical number.

[0165] Although we have used the term "daily" here, this is merely an example based on the assumption that the production line PL starts operating on a daily basis, and does not limit the timing at which the SEQ number counting begins.

[0166] 15 is merely one example of linking manufacturing information and product information, and of course, other methods can also be used. As another example, if the conveying speed of absorber conveying path R2 is constant, it is possible to determine the corresponding plate Pt from the time when a defect in an absorber Ab was discovered, the distance from that absorber Ab to the stacking unit 100, and the number of absorbers Ab within that distance.

[0167] Returning to the explanation of Figure 14, the "Pulp Type" item in the "Product Information" field stores data indicating the type of pulp used to manufacture the diaper D with the corresponding product number (here, "Type b"). It is believed that the likelihood of clogging varies depending on the pulp type. The "SAP Moisture Content" field stores data indicating the moisture content of the SAP used to manufacture the diaper D with the corresponding product number.

[0168] Although not shown in Fig. 14, the "product information" includes information related to not only the finished product of diaper D but also semi-finished products. Therefore, for example, data of an image (see Fig. 12) such as a binarized image obtained by binarizing the X-ray image of the semi-finished product shown in Fig. 9 may be included in the product information. Furthermore, the image data may be an image other than a binarized image or a brightness distribution image.

[0169] The analysis unit 14c, which will be described later, can determine whether or not there is an abnormality in at least the stacked unit 100 by analyzing the state of the stacked unit 100 based on the various pieces of information shown in FIGS.

[0170] Returning to the explanation of Fig. 11, the control unit 14 is a controller, and is realized by, for example, a CPU (Central Processing Unit) or an MPU (Micro Processing Unit) executing various programs stored in the storage unit 13 using a RAM (Random Access Memory) as a work area. The control unit 14 can also be realized by, for example, an integrated circuit such as an ASIC (Application Specific Integrated Circuit) or an FPGA (Field Programmable Gate Array).

[0171] The control unit 14 has a manufacturing information acquisition unit 14a, a product information acquisition unit 14b, an analysis unit 14c, a determination unit 14d, and an output unit 14e, and realizes or executes the functions and actions of information processing described below.

[0172] The manufacturing information acquisition unit 14a acquires manufacturing information related to the manufacturing of the diaper D from the various sensors Sr and the manufacturing management device 20 via the communication unit 11. The manufacturing information acquisition unit 14a also stores the acquired manufacturing information in the acquired information DB 13a.

[0173] The product information acquisition unit 14b acquires product information about the diaper D from the various sensors Sr and the manufacturing management device 20 via the communication unit 11. The product information acquisition unit 14b also stores the acquired product information in the acquired information DB 13a.

[0174] The analysis unit 14c analyzes the state of the stacked unit 100 based on the manufacturing information and product information stored in the acquired information DB 13a, using various state analysis models stored in the state analysis model DB 13b.

[0175] Here, a specific example of the analysis process using the state analysis model executed by the analysis unit 14c will be described with reference to Figs. 16 to 18. Fig. 16 is a diagram (part 1) showing a specific example of the analysis process. Fig. 17 is a diagram (part 2) showing a specific example of the analysis process. Fig. 18 is a diagram (part 3) showing a specific example of the analysis process.

[0176] In the simplest case, the analysis unit 14c uses a state analysis model that uses a predetermined abnormality determination threshold to analyze the state of the stack unit 100. In this case, the analysis unit 14c analyzes that there is an abnormality in at least the stack unit 100 when the sensor data exceeds the abnormality determination threshold or is equal to or less than the abnormality determination threshold depending on the type of each sensor Sr.

[0177] 16, the analysis unit 14c analyzes the state of each pipe 106 by using a state analysis model provided for each of pipes A, B, ... of the stacked unit 100. Then, the analysis unit 14c generates an analysis result of the entire stacked unit 100 based on the analysis result of each of the pipes 106.

[0178] In such a case, the analysis unit 14c analyzes that there is an abnormality in the entire stack unit 100 when, for example, an abnormality is found in at least one of the analysis results of each pipe 106. Furthermore, the analysis unit 14c analyzes that there is an abnormality in the entire stack unit 100 when, for example, an abnormality is found in a majority of the analysis results of each pipe 106. Furthermore, the analysis unit 14c analyzes that there is an abnormality in the entire stack unit 100 when, for example, an abnormality is found in all of the analysis results of each pipe 106.

[0179] Note that the example in Figure 16 shows an example based on sensor data provided at least in each pipe 106 of the stacking section 100, but it is also possible to use a state analysis model corresponding to each of the various sensors Sr in the entire production line PL.

[0180] 17, the analysis unit 14c analyzes the state of the stacked unit 100 by, for example, multivariate analysis based on sensor data from the various sensors Sr. In this case, the analysis unit 14c calculates an evaluation score indicating the state of the stacked unit 100 by using, for example, a multivariate analysis model included as a state analysis model in the state analysis model DB 13b.

[0181] The multivariate analysis model allows the analysis unit 14c to calculate an evaluation score for the state of the stacked portion 100 by solving a statistical formula for abnormality prediction using the sensor data of the various sensors Sr, the aforementioned manufacturing information, and each element of the product information as explanatory variables.

[0182] At this time, the explanatory variables may be weighted appropriately according to the conditions indicated by the elements of the manufacturing information and the product information. For example, the explanatory variables indicating an abnormality in the plate Pt may be weighted according to the number of days until the scheduled replacement date of the plate Pt, so that the weight is heavier the longer the number of days and lighter the shorter the number of days.

[0183] 18, the analysis unit 14c analyzes the state of the stacking unit 100 by using, for example, a normal state model included as a state analysis model in the state analysis model DB 13b. The normal state model is a learning model generated by machine learning the correlation of the sensor data of the various sensors Sr when the production line PL is operating normally.

[0184] The normal state model calculates the degree of deviation from the normal state by inputting, for example, real-time sensor data from various sensors Sr. As the machine learning algorithm, for example, a deep learning algorithm or the like is used.

[0185] When a machine learning algorithm is used, the normal state model may be one that calculates the degree of deviation from a normal distribution state when an image showing the distribution state described above is input by, for example, the camera 202c. Furthermore, when the normal state model shown in Fig. 18 is used, the degree of deviation from the normal state is determined, so it is also useful for detecting signs of abnormalities that do not progress to abnormalities.

[0186] Returning to the description of Fig. 11, the determining unit 14d determines, based on the analysis result by the analyzing unit 14c, whether or not there is an abnormality in at least the stacked unit 100. The output unit 14e outputs the determination result by the determining unit 14d.

[0187] The output unit 14e outputs the determination result to the HMI unit 12. The output unit 14e also outputs the determination result to the user terminal 500 via the communication unit 11. At this time, the output unit 14e converts the determination result into instructions for, for example, an operator, and outputs the instructions to the HMI unit 12 and / or the user terminal 500. The instructions include the operation details of the operator with respect to the various mechanisms Mc, etc.

[0188] If the period until the next scheduled maintenance date is short, the output unit 14e outputs instructions for boost control that aims to extend the life of the plate Pt in the short term until then. Specifically, if the analysis result by the analysis unit 14c indicates that the plate Pt is clogged, for example, the output unit 14e outputs instructions to have the worker increase the airflow rate of the intake fan 108. In similar cases, the output unit 14e also outputs instructions to adjust the opening degree of the damper Dp. In similar cases, the output unit 14e also outputs instructions to have the worker clean the plate Pt.

[0189] Furthermore, if the various mechanisms Mc can be automatically controlled, the output unit 14e generates a control signal for controlling the various mechanisms Mc as a determination result and outputs it to the various mechanisms Mc.

[0190] [3. Processing Procedure] Next, a processing procedure executed by the monitoring device 10 according to the embodiment will be described with reference to Fig. 19. Fig. 19 is a flowchart showing the processing procedure executed by the monitoring device 10 according to the embodiment.

[0191] First, the manufacturing information acquiring unit 14a acquires manufacturing information relating to the manufacturing of diapers from at least a sensor provided in the stacking unit 100 (step S101).

[0192] Then, the product information acquisition unit 14b acquires product information relating to the diaper D products in the production line PL (step S102).

[0193] Then, the storage unit 13 stores the manufacturing information and the product information in association with each other (step S103).

[0194] Furthermore, the determination unit 14d determines whether or not there is an abnormality at least in the stacking unit 100 based on the stored manufacturing information and product information (step S104). Then, the output unit 14e outputs the determination result by the determination unit 14d (step S105), and the monitoring device 10 repeats the processes from step S101.

[0195] Although pressure sensors, flow rate sensors, displacement sensors, cameras, temperature sensors, and humidity sensors have been cited as examples of the various sensors Sr up to now, the types of sensors are not limited thereto. Therefore, any sensor that is provided in the absorbent article production line PL may be used, such as a tension sensor that measures the tension of a continuous web.

[0196] [4. Other] Of the above processes, all or part of the processes described as being performed automatically may be performed manually. Furthermore, all or part of the processes described as being performed manually may be performed automatically using known methods. Furthermore, the information, including the processing procedures, specific names, various data, and parameters shown in the above documents and drawings, may be changed as desired unless otherwise specified. For example, the various information shown in each drawing is not limited to the information shown.

[0197] Furthermore, the components of each device shown in the figure are functional concepts and do not necessarily have to be physically configured as shown. In other words, the specific form of distribution and integration of each device is not limited to that shown. Furthermore, all or part of each component may be functionally or physically distributed and integrated in any unit depending on various loads, usage conditions, etc. Furthermore, each of the processes described above may be executed in appropriate combinations within a range that does not contradict each other.

[0198] [5. Hardware Configuration] The monitoring device 10 according to the above-described embodiment is realized by a computer 1000 having a configuration as shown in Fig. 20, for example. Fig. 20 is a diagram showing an example of a hardware configuration. The computer 1000 is connected to an output device 1010 and an input device 1020, and is connected to a calculation device 1030, a cache 1040 which is a primary storage device, a memory 1050 which is a secondary storage device, an output IF (Interface) 1060, an input IF 1070, and a network IF 1080 via a bus 1090.

[0199] The arithmetic device 1030 operates based on programs stored in the cache 1040 or memory 1050, programs read from the input device 1020, etc., and executes various processes. The cache 1040 is a cache such as a RAM that temporarily stores data used by the arithmetic device 1030 for various calculations. The memory 1050 is a storage device in which data used by the arithmetic device 1030 for various calculations and various databases are registered, and is a memory realized by a ROM (Read Only Memory), an HDD (Hard Disk Drive), a flash memory, etc.

[0200] The output IF 1060 is an interface for transmitting information to be output to an output device 1010 that outputs various types of information, such as a monitor or a printer, and may be realized by a connector conforming to a standard such as USB (Universal Serial Bus), DVI (Digital Visual Interface), or HDMI (High Definition Multimedia Interface), etc. On the other hand, the input IF 1070 is an interface for receiving information from various input devices 1020, such as a mouse, keyboard, scanner, etc., and may be realized by a USB, etc.

[0201] For example, the input device 1020 may be realized by a device that reads information from an optical recording medium such as a CD (Compact Disc), a DVD (Digital Versatile Disc), or a PD (Phase Change Rewritable Disk), a magneto-optical recording medium such as an MO (Magneto-Optical disk), a tape medium, a magnetic recording medium, or a semiconductor memory, etc. The input device 1020 may also be realized by an external storage medium such as a USB memory.

[0202] The network IF 1080 has a function of receiving data from other devices via the network N and sending it to the arithmetic device 1030, and also a function of transmitting data generated by the arithmetic device 1030 to other devices via the network N.

[0203] Here, the arithmetic device 1030 controls the output device 1010 and the input device 1020 via the output IF 1060 and the input IF 1070. For example, the arithmetic device 1030 loads a program from the input device 1020 or the memory 1050 onto the cache 1040 and executes the loaded program. For example, when the computer 1000 functions as the monitoring device 10, the arithmetic device 1030 of the computer 1000 executes the program loaded onto the cache 1040 to realize the functions of the manufacturing information acquisition unit 14a, the product information acquisition unit 14b, the analysis unit 14c, the determination unit 14d, and the output unit 14e.

[0204] The embodiments of the present application have been described in detail above with reference to the drawings. However, these are merely examples, and the embodiments of the present application can be implemented in other forms that incorporate various modifications and improvements based on the knowledge of those skilled in the art, including the aspects described in the Disclosure of the Invention section. Furthermore, the above-mentioned "section, module, unit" can be read as "means," "circuit," etc. [Explanation of symbols]

[0205] 1. Manufacturing System 10 Monitoring equipment 13 Storage section 14 Control Unit 14a Manufacturing information acquisition department 14b Product information acquisition department 14c Analysis Department 14d Judgment section 14e Output section 50 Manufacturing equipment 100 Laminated section 103 Rotating Drum 103a Recess 103b Rotating part 106 Piping 108 Intake fan D. Diapers PL production line Pt King Rate Sr Various sensors

Claims

1. In an apparatus for manufacturing absorbent articles, a lamination unit that laminates the pulverized and / or defibrated material into an absorbent body in the absorbent article; a first acquisition unit that acquires first information, which is information related to the manufacture of the absorbent article, from at least a sensor provided in the stacking unit; a second acquisition unit that acquires second information that is information about the absorbent article product in the manufacturing line of the absorbent article; a storage unit that stores the first information and the second information in association with each other; a determination unit that determines whether or not an abnormality exists in at least the stacked portion based on the first information and the second information; an output unit that outputs a determination result by the determination unit; Equipped with The laminated portion is a rotating drum having a rotating part that is provided in an annular shape and is rotatable around a central axis of the ring, the rotating part having a plurality of recesses or a continuous series of recesses formed along an outer peripheral surface of the rotating part; suction portions provided opposite the inner circumferential surface and the outer circumferential surface of the rotating portion; an intake fan that sucks the material into the recess by an intake air flow through a pipe connected to the suction unit behind the rotating drum, stacking the absorbent body and removing the stacked absorbent body from the recess; Equipped with The sensor is provided in the pipe. An apparatus for manufacturing absorbent articles, comprising:

2. The sensor is provided in plurality on the piping. The absorbent article manufacturing apparatus according to claim 1 .

3. The piping is A plurality of the suction units are connected to the suction unit, The sensor A plurality of pipes are provided in each straight section. The absorbent article manufacturing apparatus according to claim 2 .

4. The first information is Contains information about the pressure and / or flow rate of intake air flowing through said piping The absorbent article manufacturing apparatus according to claim 2 or 3.

5. The sensor At least one of a pressure sensor, a flow rate sensor, and a flow velocity sensor. The absorbent article manufacturing apparatus according to claim 4 .

6. The recessed portion is formed by replaceably provided plates, The first information includes information about the plate. The absorbent article manufacturing apparatus according to claim 2.

7. The information about the plate includes: The information includes at least one of information regarding the identification of the plate, information regarding the previous maintenance, and information regarding the next replacement. The absorbent article manufacturing apparatus according to claim 6.

8. The second information is Contains information about the finished and / or semi-finished products of said products 4. The absorbent article manufacturing apparatus according to claim 1, 2 or 3.

9. an imaging sensor provided downstream of the stacking unit in the manufacturing line; Furthermore, The second information is information about an image showing the state of the absorber captured by the image sensor The absorbent article manufacturing apparatus according to claim 8 .

10. The material is The material includes at least one of pulp, synthetic fiber, and polymer absorbent material; The second information includes information about the material.

4. The absorbent article manufacturing apparatus according to claim 1, 2 or 3.

11. An apparatus for manufacturing absorbent articles, comprising: a lamination unit that laminates the pulverized and / or defibrated material into an absorbent body in the absorbent article; a first acquisition unit that acquires first information, which is information related to the manufacture of the absorbent article, from at least a sensor provided in the stacking unit; a second acquisition unit that acquires second information that is information about the absorbent article product in the manufacturing line of the absorbent article; a storage unit that stores the first information and the second information in association with each other; a determination unit that determines whether or not an abnormality exists in at least the stacked portion based on the first information and the second information; an output unit that outputs a determination result by the determination unit; Temperature and / or humidity sensors Equipped with The first information is Information about the temperature measured by the temperature sensor and / or information about the humidity measured by the humidity sensor An apparatus for manufacturing absorbent articles, comprising:

12. a manufacturing method carried out by a manufacturing device comprising: a lamination unit that laminates absorbent bodies in an absorbent article from pulverized and / or defibrated material, the lamination unit having a rotating unit that is provided in an annular shape and is rotatable around the central axis of the ring, a rotating drum having a plurality of recesses or continuous recesses formed along the outer peripheral surface of the rotating unit; suction units that are provided opposite the inner peripheral surface and the outer peripheral surface of the rotating unit; an intake fan that uses an intake air flow through a pipe connected to the suction unit at the rear of the rotating drum to suck the material into the recesses to laminate the absorbent bodies and to remove the laminated absorbent bodies from the recesses; and a sensor that is provided on the pipe, a first acquisition step of acquiring first information, which is information related to the manufacture of the absorbent article, from the sensor; a second acquisition step of acquiring second information which is information relating to the absorbent article product in the manufacturing line of the absorbent article; a storage step of storing the first information and the second information in association with each other; a determination step of determining whether or not an abnormality exists in at least the stacked portion based on the first information and the second information; an output step of outputting the determination result in the determination step; A method for manufacturing an absorbent article, comprising:

13. A computer of a manufacturing device comprising: a lamination section for laminating absorbents in an absorbent article from crushed and / or defibrated material, the lamination section being provided in an annular shape and having a rotating section that can rotate around the central axis of the annular shape, a rotating drum having a plurality of recesses or continuous recesses formed along the outer peripheral surface of the rotating section; a suction section provided opposite the inner peripheral surface and the outer peripheral surface of the rotating section; an intake fan that uses an intake air flow through a pipe connected to the suction section at the rear of the rotating drum to suck the material into the recesses to laminate the absorbents and to remove the laminated absorbents from the recesses; and a sensor provided on the pipe, a first acquisition step of acquiring first information, which is information relating to the manufacture of the absorbent article, from the sensor; a second acquisition step of acquiring second information which is information relating to the absorbent article product in the manufacturing line of the absorbent article; a storage step of storing the first information and the second information in association with each other; a determination step of determining whether or not an abnormality exists in at least the stacked portion based on the first information and the second information; an output step for outputting a determination result obtained by the determination step; A program characterized by executing the following.

14. A manufacturing method carried out by a manufacturing device having a lamination unit that laminates an absorbent body in an absorbent article from pulverized and / or defibrated material, and a temperature sensor and / or a humidity sensor, a first acquisition step of acquiring first information, which is information related to the manufacture of the absorbent article, including at least information related to the temperature measured by the temperature sensor and / or information related to the humidity measured by the humidity sensor; a second acquisition step of acquiring second information which is information relating to the absorbent article product in the manufacturing line of the absorbent article; a storage step of storing the first information and the second information in association with each other; a determination step of determining whether or not an abnormality exists in at least the stacked portion based on the first information and the second information; an output step of outputting the determination result in the determination step; A method for manufacturing an absorbent article, comprising:

15. A manufacturing device having a lamination unit for laminating an absorbent body in an absorbent article from pulverized and / or defibrated materials, and a temperature sensor and / or a humidity sensor, a first acquisition step of acquiring first information, which is information related to the manufacture of the absorbent article, including at least information related to the temperature measured by the temperature sensor and / or information related to the humidity measured by the humidity sensor; a second acquisition step of acquiring second information which is information relating to the absorbent article product in the manufacturing line of the absorbent article; a storage step of storing the first information and the second information in association with each other; a determination step of determining whether or not an abnormality exists in at least the stacked portion based on the first information and the second information; an output step for outputting a determination result obtained by the determination step; A program characterized by executing the following.

16. An apparatus for manufacturing absorbent articles, comprising: a lamination unit that laminates the pulverized and / or defibrated material into an absorbent body in the absorbent article; a first acquisition unit that acquires first information, which is information related to the manufacture of the absorbent article, from at least a sensor provided in the stacking unit; a second acquisition unit that acquires second information that is information about the absorbent article product in the manufacturing line of the absorbent article; a storage unit that stores the first information and the second information in association with each other; a determination unit that determines whether or not an abnormality exists in at least the stacked portion based on the first information and the second information; an output unit that outputs a determination result by the determination unit; Equipped with The laminated portion is a recess formed by a replaceable plate and in which the absorbent body is stacked; The first information includes information about the plate. An apparatus for manufacturing absorbent articles, comprising:

17. A manufacturing method carried out by a manufacturing device having a lamination section for laminating absorbents in an absorbent article from crushed and / or defibrated material, the lamination section being formed by replaceable plates and having recesses in which the absorbents are laminated, comprising: a first acquisition step of acquiring first information, which is information related to the manufacture of the absorbent article and includes information related to the plate, from at least a sensor provided in the stacking unit; a second acquisition step of acquiring second information which is information relating to the absorbent article product in the manufacturing line of the absorbent article; a storage step of storing the first information and the second information in association with each other; a determination step of determining whether or not an abnormality exists in at least the stacked portion based on the first information and the second information; an output step of outputting the determination result in the determination step; A method for manufacturing an absorbent article, comprising:

18. A manufacturing device having a lamination section for laminating absorbent bodies in an absorbent article from crushed and / or defibrated materials, the lamination section being formed by a replaceable plate, and having a recess in which the absorbent bodies are laminated, a first acquisition step of acquiring first information, which is information relating to the manufacture of the absorbent article and includes information relating to the plate, from at least a sensor provided in the stacking unit; a second acquisition step of acquiring second information which is information relating to the absorbent article product in the manufacturing line of the absorbent article; a storage step of storing the first information and the second information in association with each other; a determination step of determining whether or not an abnormality exists in at least the stacked portion based on the first information and the second information; an output step for outputting a determination result obtained by the determination step; A program characterized by executing the following.

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