Virtual Frame Reference for Manufacturing Component Alignment
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Solution Overview
Problem
Existing manufacturing processes for consumer goods face challenges in ensuring consistent component placement, leading to variations in product quality and consumer acceptance, particularly in disposable absorbent products where off-center or skewed components can result in leakage or aesthetic issues.
Innovation Solution
A controller system using a virtual frame of reference to analyze electronic images of components and generate phasing commands for machines, reducing the need for additional sensors and manual adjustments, thereby improving consistency and reducing human error.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual positioning methods are used for components, then ease of operation is maintained, but manufacturing precision deteriorates due to human error and inconsistency
Solution Approach 1:
The patent replaces manual mechanical positioning with an automated vision system that uses electronic imaging and computer processing to detect component positions and generate phasing commands, thereby improving manufacturing precision while reducing human error
Solution Approach 2:
The vision system automatically captures images, processes component positions, and generates control commands without continuous human intervention, allowing the system to self-regulate and maintain consistent positioning precision
2Manufacturing precision
If additional sensors and manual adjustments are added to improve positioning accuracy, then manufacturing precision improves, but device complexity increases
Solution Approach 1:
The vision system serves multiple functions: capturing component images, determining positions, comparing with setpoints, and generating phasing commands, thereby achieving high positioning accuracy without requiring multiple separate devices
Solution Approach 2:
The patent combines image capture, position analysis, comparison, and control command generation into a single integrated vision system, reducing the need for additional sensors and manual adjustment mechanisms
3Productivity
If automated vision systems are implemented, then productivity improves through automation, but device complexity increases
Solution Approach 1:
The vision system continuously captures component positions, compares them with setpoints, and generates phasing commands to correct deviations, creating a closed-loop feedback system that automates positioning control
Solution Approach 2:
The controller acts as an intermediary between the vision system and the phasing mechanism, processing image data and translating it into control commands that adjust component positioning
Data Source
AI summary
The system and method uses a virtual frame of reference to evaluate and control a manufacturing system. Electronic images from a vision system may be analyzed using the virtual frame of reference to control the phasing of devices in the manufacturing system and to generate alerts.