Failure Detection System for Absorbent Article Manufacturing
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Solution Overview
Problem
Conventional imaging systems in absorbent article manufacturing lines can detect failure locations but struggle to identify the specific steps where processing failures occur, making it difficult to assess the overall manufacturing status.
Innovation Solution
A failure detection system comprising an image processing unit, failure detection unit, image display unit, failure step determination unit, and step control unit that acquires and compares morphological images across multiple steps to detect and determine the cause of failures, and control parameters to address issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a camera is installed at a plurality of positions on the manufacturing line to detect failure locations promptly, then the detection speed and coverage are improved, but the ability to identify the specific step where the failure occurred deteriorates
Solution Approach 1:
The manufacturing line is divided into multiple discrete steps (web conveying step, absorber arranging step, elastic member arranging step, folding step, cutting step), and images are captured at each step. The image display unit then segments the display by showing only the images from steps occurring before the detected failure location, allowing operators to quickly identify which specific step caused the failure without being overwhelmed by all images from the entire manufacturing line.
Solution Approach 2:
The image display unit acts as an intermediary between the multiple cameras and the operator. It receives images from all camera positions, processes them by filtering out images from steps after the failure occurrence, and presents only the relevant pre-failure images to the operator. This intermediary function resolves the contradiction by maintaining comprehensive detection coverage while providing focused failure step identification.
2Loss of information
If images from all manufacturing steps are displayed to check overall manufacturing status, then comprehensive monitoring is achieved, but the time to identify the specific failure step increases
Solution Approach 1:
The system performs preliminary action by capturing and storing images at each manufacturing step as they occur, rather than displaying all images simultaneously. When a failure is detected, the system has already prepared the images from relevant steps for immediate display, eliminating the need to search through all manufacturing images and reducing the time to identify the failure step.
Solution Approach 2:
The image display unit dynamically adjusts which images are displayed based on the detected failure location. Instead of a static display showing all images from all steps, the system dynamically filters and presents only the images from steps occurring before the failure, optimizing the information presented to the operator based on real-time failure detection data.
Data Source
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AI summary
A failure detection system 100 includes an image processing unit 130 configured to acquire a morphological image illustrating a morphology of the absorbent article after processing of the absorbent article, in each of the plurality of steps, a failure detection unit 140 configured to detect the existence of a failure location of the absorbent article after processing, based on the morphological image acquired by the image processing unit 130, and an image display unit 120 configured to display an image of the absorbent article after processing, when a failure location of the absorbent article is detected by the failure detection unit 140.