Absorbent Article Reject System Using Timestamped Sensor Signals
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Solution Overview
Problem
Existing absorbent article converting lines face challenges in accurately tracking defect locations due to asynchronous sensor and control system operations, leading to unnecessary rejection of non-defective articles to compensate for timing delays, resulting in inefficiencies at high production speeds.
Innovation Solution
Implementing a synchronized clock system across sensors and controllers connected via a communication network, allowing for precise timestamp correlation and accurate defect tracking, enabling the rejection of only defective articles without rejecting non-defective ones.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If asynchronous sensor and control system operations are used, then device complexity is reduced, but manufacturing precision deteriorates due to inaccurate defect location tracking
Solution Approach 1:
The patent introduces a timestamp as an intermediary element that mediates between the sensor detection time and the controller processing time. Each sensor signal is tagged with a precise timestamp, allowing the controller to accurately track when the defect was detected and correlate it with the corresponding product position, thereby maintaining manufacturing precision without increasing control system complexity.
Solution Approach 2:
The patent applies preliminary action by pre-tagging sensor signals with timestamps before they are processed by the controller. This preliminary timestamping action enables accurate defect location tracking to be established in advance, so that when the controller receives the signals, the timing information is already available, eliminating the need for complex real-time synchronization.
2Ease of operation
If asynchronous sensor and control system operations are used, then ease of operation is improved, but reliability deteriorates due to incorrect defect identification
Solution Approach 1:
The timestamp acts as an intermediary that carries timing information from the sensor through the communication network to the controller. This intermediary element ensures that even with asynchronous operations and variable communication delays, the controller can reliably identify which product corresponds to each defect detection, maintaining high reliability while keeping the system easy to operate.
Solution Approach 2:
The system implements feedback by using the timestamp information to verify and confirm the correct identification of defective products. The controller can trace back from the defect detection signal, using the timestamp to identify the exact product position, thereby providing reliable defect identification that enhances system reliability without complicating operation.
3Reliability
If a large number of diapers are rejected to compensate for control system delays, then reliability of defect rejection is improved, but productivity deteriorates due to unnecessary rejection of non-defective articles
Solution Approach 1:
The patent applies preliminary action by pre-tagging each sensor signal with a timestamp that identifies the exact product position when the defect was detected. This preliminary timing information allows the controller to immediately and accurately identify the defective product without needing to reject multiple articles, thereby maintaining high reliability of defect rejection while preventing unnecessary rejection of non-defective articles and preserving productivity.
Solution Approach 2:
The patent replaces the mechanical approach of rejecting multiple articles as a safety margin with an information-based approach using timestamps. Instead of mechanically rejecting a large number of diapers to account for timing uncertainties, the system uses timestamp information to precisely identify and reject only the defective article, substituting information processing for mechanical over-rejection and thereby maintaining productivity.
4Manufacturing precision
If precise timestamp correlation is implemented, then manufacturing precision is improved, but device complexity increases due to synchronized clock system
Solution Approach 1:
The timestamp serves as an intermediary that encapsulates the complexity of clock synchronization within a simple data structure. Rather than requiring complex real-time synchronization protocols between sensor and controller clocks, the system uses timestamps as intermediary markers that carry timing information, simplifying the overall system architecture while maintaining manufacturing precision.
5Loss of information
If timestamp correlation is used, then loss of information is reduced, but device complexity increases due to communication network requirements
Solution Approach 1:
The timestamp acts as an intermediary information element that prevents loss of defect location data during communication between sensor and controller. By embedding timing information as a timestamp in the data stream, the system preserves critical location information without requiring complex communication protocols, thereby reducing information loss while keeping the communication network infrastructure relatively simple.
Data Source
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AI summary
The present disclosure relates to systems and processes for detecting and rejecting defective absorbent articles from a converting line. In particular, the systems and methods may utilize feedback from technologies, such as vision systems, sensors, remote input and output stations, and controllers with synchronized embedded clocks to accurately correlate inspection results and measurements from an absorbent article converting process. As such, the systems and methods may accurately apply the use of precision clock synchronization for both instrumentation and control system devices on a non deterministic communications network. In turn, the clock synchronized control and instrumentation network may be used to control a reject system on converters of absorbent articles. In some embodiments, the controller will reject only defective absorbent articles without the need to reject non defective absorbent articles.