Autosetpoint registration control system and method associated with a web converting manufacturing process

Abstract

Systems and methods for providing registration control in connection with a web converting manufacturing process such as that used for manufacturing disposable absorbent garments. Some of the disclosed embodiments include relating inspection data, such as product (or process) attribute data, to data from other manufacturing-related systems. Also disclosed are systems and methods for linking product (or process) attribute data obtained during the manufacturing process with one or more data sources including raw material data, process setting data, product quality data, and/or productivity data. Also disclosed are systems and methods for identifying manufacturing set point changes and automatically implementing such changes and automated web steering changes based on data from one or more inspection systems.

1 . An automatic registration set point control system comprising: 
 an inspection system for automatically inspecting a component part of a composite product produced during a production run of a high speed web converting manufacturing process for producing the composite product from a sequential addition of component parts during a production run of composite products, said inspection system providing an inspection parameter indicative of a characteristic of the inspected component part;    a registration control system responsive to a set point parameter which is a function of the inspection parameter for controlling a registration of the component part; and    a communication network linking the inspection system and the registration control system.    
     
     
         2 . A system as set forth in  claim 1  further comprising an information exchange obtaining via the communications network the provided indication of the inspection parameter and determining a set point parameter as a function of the inspection parameter.  
     
     
         3 . A system as set forth in  claim 2  wherein the information exchange system obtains a plurality of said inspection parameters provided by the inspection system, said information exchange system determining a mathematical characteristic of said plurality of inspection parameters and wherein said information exchange system compares said mathematical characteristic to a target whereby the set point parameter determined by the information exchange is a function of a difference between the mathematical characteristic and the target.  
     
     
         4 . A system as set forth in  claim 3  wherein the information exchange system is configured such that the mathematical characteristic comprises an average of the obtained plurality of inspection parameters.  
     
     
         5 . A system as set forth in  claim 3  wherein the information exchange system is configured such that the mathematical characteristic comprises a standard deviation of the obtained plurality of inspection parameters.  
     
     
         6 . A system as set forth in  claim 2  further comprising an operator display responsive to the set point parameter for displaying an indication of the set point parameter to an operator associated with the production line.  
     
     
         7 . A system as set forth in  claim 2  wherein the communication network comprises a distributed node, shared memory system and wherein at least the inspection system and information exchange system comprise nodes of said communication network.  
     
     
         8 . A system as set forth in  claim 1:   wherein the inspection system determines the inspection parameter and wherein said inspection system determines the set point parameter as a function of the determined inspection parameter; and    wherein the registration control system obtains the set point parameter via the communication network and controls a registration of the component part as a function of the determined set point parameter.    
     
     
         9 . A system as set forth in  claim 1  wherein 
 the registration control system obtains the inspection parameter via the communication network and determines a registration set point adjustment as a function of the inspection parameter.    
     
     
         10 . An automatic registration set point control method, said method being suitable for use in connection with a high speed web converting manufacturing process for producing a composite article from a sequential addition of component parts during a production run of composite articles, said method comprising: 
 detecting a placement of a first component part of a first composite article being produced;    providing a first signal indicative of the placement of the first component part of the first composite article;    detecting a placement of a second component part of the first composite article being produced;    providing a second signal indicative of the placement of the second component part of the first composite article;    detecting an absolute measurement of the placement of said second component part relative to said first component part; and    comparing said absolute measurement to a target indicative of a desired relative offset between said first and second signals.    
     
     
         11 . The method of  claim 10  further comprising adjusting a set point controlling placement of a second component part with respect to a second composite article produced subsequent to the first composite article during the production run as a function of a difference between the absolute measurement and the target such that the desired relative offset between the first and second signals is substantially achieved with respect to the second component part.  
     
     
         12 . The method of  claim 10  further comprising controlling placement of a second component part with respect to a second composite article produced subsequent to the first composite article during the production run as a function of a difference between the absolute measurement and the target such that the desired relative offset between the first and second signals is substantially achieved with respect to the second component part.  
     
     
         13 . An automatic registration set point control method comprising: 
 automatically inspecting a component part of a composite product produced during a production run of a high speed web converting manufacturing process for producing the composite product from a sequential addition of component parts during a production run of composite products,    providing an inspection parameter indicative of a characteristic of the inspected component part; and    controlling in response to a set point parameter which is a function of the inspection parameter a registration of the component part.    
     
     
         14 . A method as set forth in  claim 13  further comprising obtaining via a communications network the provided indication of the inspection parameter and determining a set point parameter as a function of the inspection parameter.  
     
     
         15 . A method as set forth in  claim 14  further comprising obtaining a plurality of said inspection parameters, determining a mathematical characteristic of said plurality of inspection parameters and comparing said mathematical characteristic to a target whereby the set point parameter is a function of a difference between the mathematical characteristic and the target.  
     
     
         16 . A method as set forth in  claim 15  wherein the mathematical characteristic comprises an average of the obtained plurality of inspection parameters.  
     
     
         17 . A method as set forth in  claim 15  wherein the mathematical characteristic comprises a standard deviation of the obtained plurality of inspection parameters.  
     
     
         18 . A method as set forth in  claim 14  further displaying an indication of the set point parameter to an operator associated with the production line.  
     
     
         19 . A method as set forth in  claim 13  further comprising: 
 determining the inspection parameter and determining the set point parameter as a function of the determined inspection parameter; and    obtaining the set point parameter via a communication network and controlling a registration of the component part as a function of the determined set point parameter.    
     
     
         20 . A method as set forth in  claim 13  further comprising obtaining the inspection parameter via a communication network and determining a registration set point adjustment as a function of the inspection parameter.