Sanitary Article Line Correction Using Image-Based Defect Mapping
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Solution Overview
Problem
Existing production lines for absorbent sanitary articles, such as nappies and incontinence pads, face high complexity and costs due to the need for multiple video cameras and complex computers for monitoring and correcting production errors, requiring advanced technical knowledge and resulting in high reject rates.
Innovation Solution
A method for corrective action on the production line that uses a simplified monitoring system with fewer sensors and industrial-type computers, providing step-by-step instructions for operators to correct defects and allowing for automatic adjustment of operating parameters, reducing complexity and costs while minimizing rejects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple video cameras and complex computers are used for monitoring each operating station, then production errors can be detected and corrected, but the device complexity and cost increase significantly
Solution Approach 1:
The patent combines multiple monitoring functions into a single video camera positioned at the line entrance, rather than requiring separate cameras at each operating station. This merging approach maintains production error detection capability while significantly reducing system complexity and cost.
Solution Approach 2:
The single video camera system is designed to monitor multiple operating stations sequentially as products move through the line. This multi-functional approach allows one camera to perform the monitoring role that previously required multiple dedicated cameras, reducing overall system complexity.
2Measurement precision
If complex computers are used for image analysis, then production errors can be identified accurately, but the cost and technical knowledge requirements increase
Solution Approach 1:
The patent employs simpler, more affordable computing equipment rather than expensive complex computers. The system uses basic image processing capabilities that can be implemented with less costly hardware, reducing the overall system cost while maintaining adequate error detection accuracy.
Solution Approach 2:
The patent replaces complex mechanical image analysis systems with simplified electronic processing. By using straightforward computer vision algorithms and basic image processing techniques, the system achieves error detection without requiring expensive specialized hardware or advanced technical knowledge.
3Device complexity
If a single video camera is used instead of multiple cameras, then device complexity is reduced, but the ability to monitor multiple operating stations may be compromised
Solution Approach 1:
The system uses the dynamic movement of products through the production line to enable a single camera to monitor multiple stations. As products move sequentially past the camera, each operating station is captured in different frames, allowing comprehensive monitoring of all stations with one camera position.
Solution Approach 2:
The patent adds the time dimension to the monitoring process by capturing images at different moments as products move through the line. This temporal dimension allows a single spatial position (one camera) to effectively monitor multiple operating stations that would otherwise require multiple simultaneous camera positions.
Data Source
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AI summary
A method for corrective action on the operation of a line for the production of absorbent sanitary articles, such as nappies for babies or incontinence pads for adults, sanitary towels or the like, comprises capturing at least one image of each article (2) being fed out of the line (1); using the image to define first parameters indicating the positioning and/or assembly and/or shape of at least one respective component; detecting a production defect if at least one of the first parameters is outside a respective acceptability range; identifying second, line operating parameters which are used to indicate if the first parameter is outside the respective acceptability range; comparing the line (1) operating parameters with respective third, reference parameters indicating optimum line (1) operation; using the comparison to derive a map of abnormal operating parameters; checking if each combination of abnormal operating parameters indicates a respective cause of malfunction of the line (1), the respective cause being contained in a case record of causes of malfunction which is preset in a database; defining, for each cause of malfunction encountered, the corrective action to be taken in order to eliminate the production defect.