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WO2018101457A1 - Système de contrôle de ligne de fabrication, dispositif de contrôle de ligne de fabrication, et procédé de contrôle de ligne de fabrication - Google Patents

Système de contrôle de ligne de fabrication, dispositif de contrôle de ligne de fabrication, et procédé de contrôle de ligne de fabrication Download PDF

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Publication number
WO2018101457A1
WO2018101457A1 PCT/JP2017/043265 JP2017043265W WO2018101457A1 WO 2018101457 A1 WO2018101457 A1 WO 2018101457A1 JP 2017043265 W JP2017043265 W JP 2017043265W WO 2018101457 A1 WO2018101457 A1 WO 2018101457A1
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WO
WIPO (PCT)
Prior art keywords
unit
production line
identification code
processing unit
line control
Prior art date
Application number
PCT/JP2017/043265
Other languages
English (en)
Japanese (ja)
Inventor
孝太 上野
真 小久保
尚大 平
晃央 森田
Original Assignee
花王株式会社
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from JP2017226718A external-priority patent/JP6587671B2/ja
Application filed by 花王株式会社 filed Critical 花王株式会社
Priority to CN201780066120.3A priority Critical patent/CN109891343A/zh
Priority to US16/347,487 priority patent/US20190282408A1/en
Priority to EP17876995.6A priority patent/EP3550390A4/fr
Publication of WO2018101457A1 publication Critical patent/WO2018101457A1/fr

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    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
    • A61F13/00—Bandages or dressings; Absorbent pads
    • A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B19/00—Programme-control systems
    • G05B19/02—Programme-control systems electric
    • G05B19/418—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM]
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B23/00—Testing or monitoring of control systems or parts thereof
    • G05B23/02—Electric testing or monitoring
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
    • Y02P90/02—Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

Definitions

  • the present invention relates to a manufacturing line control system, a manufacturing line control device, and a manufacturing line control method for quickly detecting an abnormal part.
  • prompt investigation of the cause may be required. For example, when a defective product is found in a quality inspection in the manufacturing process, or when a complaint is received from a consumer. Similarly, prompt investigation of the cause is required when a machine trouble occurs in the manufacturing equipment.
  • Patent Document 1 discloses a system that acquires a form image of an absorbent article, detects a defect of the absorbent article based on the form image, and identifies the occurrence location.
  • the present invention is a control system for a production line including a processing unit for obtaining a workpiece,
  • the control system includes the processing unit and a control unit that controls the processing unit,
  • the processing unit has a plurality of unit units, Each of the plurality of unit units has a unit unit identification code
  • the production line control system has an inspection unit for inspecting the workpiece,
  • the inspection unit can communicate within the control system of the production line,
  • the inspection unit includes a determination unit that determines a state of the workpiece and obtains a determination result, the determination result, and the unit unit identification code of the processing unit that has processed the workpiece that has performed the determination.
  • a production line control system comprising: a data processing unit that associates the unit unit identification code; a storage unit that stores the determination result for each unit unit identification code; and a notification unit that notifies the unit unit identification code and the determination result.
  • the present invention is a control device for a production line including a processing unit for obtaining a workpiece,
  • the control device includes the processing unit and a control unit that controls the processing unit,
  • the processing unit has a plurality of unit units, Each of the plurality of unit units has a unit unit identification code
  • the control unit has an inspection unit for inspecting a workpiece obtained by the processing unit,
  • the inspection unit can communicate within the control device,
  • the inspection unit is configured to determine a state of the workpiece and obtain a determination result; the determination result; and the unit unit identification code of the processing unit in which the workpiece that has performed the determination is processed.
  • a production line control device comprising: a data processing unit that associates the unit unit identification code; a storage unit that stores the determination result for each unit unit identification code; and a notification unit that notifies the unit unit identification code and the determination result.
  • the present invention is a method for controlling a production line comprising a plurality of processing units for producing a workpiece, Giving a unit unit identification code to each of the plurality of unit units of the processing unit; Inspecting the fabricated workpiece, Determining the state of the inspected workpiece and obtaining a determination result; Associating the determination result with the unit unit identification code of the processing unit that has processed the workpiece subjected to the determination; Storing the determination result for each unit unit identification code; There is provided a method for controlling a production line including the step of notifying the unit unit identification code and the determination result.
  • (A) is a plan view showing an example of a state in which the elastic body is normally pre-cut
  • (B) is an enlarged view of the imaging region shown in (A)
  • (C) is ( B) It is an enlarged view of the inspection area shown in the figure.
  • It is the front view which showed an example of the ultrasonic welding machine.
  • It is the fragmentary front view which showed a part of manufacturing line provided with the some process unit.
  • the present invention relates to a production line control system, a control device, and a control method for quickly detecting an abnormal part.
  • Abnormal products and defective products such as those described above are units of multiple picking used in the absorbent article manufacturing apparatus ("multiple picking up units” include a plurality of unit units that perform the same processing. Unit).
  • the present invention relates to quickly identifying an abnormal location when an abnormality occurs in one of such multiple picking units.
  • the present invention also relates to reducing the time required for adjustment and monitoring of the manufacturing apparatus in order to eliminate these problems, thereby reducing the load on maintenance.
  • an abnormal location can be detected quickly, and the time productivity of the manufacturing apparatus can be improved by reducing the time for investigating a unit that does not require maintenance.
  • slight differences in determination results occurring in specific unit units can be captured from the data for each unit unit identification number.
  • the operator of the production line can easily make adjustments to suppress the variation in products, and the quality of the workpiece can be improved.
  • the production line control system 10 of the present invention is a control system including a production unit 20 for producing a workpiece 101.
  • the production line control system 10 is also simply referred to as a control system 10.
  • a production line usually includes a plurality of processing units 20.
  • processing includes deformation processing, addition processing, removal processing, special processing, etc., or processing that combines these, and uses physical action, chemical action, physical / chemical action, etc. Refers to processing. Examples of the deformation process include stacking, compression, rolling, and the like. Examples of the additional process include welding, adhesion, and application. Examples of the removal process include cutting and cutting.
  • Special processing includes, for example, ultrasonic irradiation, laser irradiation, plasma irradiation, and the like. Further, changing the position of the article is also included in the processing as displacement processing. However, the processing examples given above are only a part and are not limited to these processing examples.
  • the processing unit 20 has a plurality of unit units 30.
  • an absorbent body manufacturing apparatus 110 is shown as the processing unit 20.
  • the unit unit 30 is a plurality of stacking concave portions 141 in the stacking machine 140 of the manufacturing apparatus 110, and is a unit that bears the same processing element.
  • Each unit unit 30 has a unit unit identification code.
  • the unit unit identification code is a code for identifying the unit unit 30 assigned to the unit unit 30 constituting the processing unit 20. As long as they can be identified, any number, letters, or a combination of numbers and letters can be used. Usually, it is represented by a natural number in order from 1. Or you may represent by a positive integer in an order from 0. Or like an alphabet, it can also be expressed as “A”, “B”, “C”,.
  • the unit unit identification code in the illustrated example is represented by a natural number of 1 to 8, such as “1”, “2”,.
  • the unit unit identification code is preferably given to the unit unit 30 in advance.
  • the control system 10 includes a control unit 11 including an inspection unit 40 that inspects the workpiece 101 processed by the processing unit 20.
  • the control unit 11 is preferably provided with a control unit 90 described later.
  • the inspection unit 40 includes an imaging unit 41 that images the workpiece 101 processed by the processing unit 20 and an illumination unit 42 that illuminates the workpiece 101.
  • the illumination unit 42 is arranged at a position facing the imaging direction of the imaging unit 41 with the workpiece 101 being an imaging object interposed therebetween.
  • the imaging unit 41 is disposed at a position where L sheets have been conveyed after processing by the processing unit 20.
  • the imaging object is on the same side as the imaging unit 41 and from the imaging unit 41 toward the processed object 101.
  • the illumination unit 42 is disposed at a position that does not interfere with the captured imaging field.
  • the inspection unit 40 includes an image processing unit 43, a determination unit 50, a data processing unit 60, a storage unit 70, and a notification unit 80.
  • the inspection unit 40 is connected so as to be able to communicate with each unit including the processing unit 20 in the control system 10 (see FIG. 1). At least communication with the control unit 90 is possible.
  • the image processing unit 43 processes the captured image obtained by the imaging unit 41 with preset contents to obtain processed data.
  • Processed data refers to data obtained as a result of image processing.
  • an image obtained by performing various types of filter processing for example, binarization processing, averaging processing, expansion processing, contraction processing, etc.
  • it is numerical data such as coordinate data, number, and degree of coincidence obtained by various feature extraction processes (area measurement, blob count, edge detection process, pattern matching process, etc.).
  • it is a combination of a captured image, an image subjected to various filter processes, and numerical data obtained by various feature extraction processes.
  • the determination unit 50 determines the state of the workpiece obtained by the machining unit by comparing the machining data obtained by the image processing unit 43 and the machining data of a normal product registered in advance. That is, the processed data obtained by the image processing unit 43 is received, it is determined whether or not the captured processed object 101 is normal using a preset threshold value, and the pass / fail data is output to the control unit 90. (See FIG. 1).
  • the data processing unit 60 associates the determination result obtained by the determination unit 50 with the unit unit identification code of the unit unit 30 that has processed the determined workpiece 101.
  • the determination result refers to data used for determination in the determination unit 50.
  • This data includes, for example, a captured image, a binarized image, the counted number of pixels, pass / fail data, a manufacturing number of the workpiece 101 when the workpiece 101 is processed, a manufacturing date, a manufacturing time, and the like. be able to.
  • the storage unit 70 stores a determination result for each unit unit identification code.
  • the capacity of a storage medium (not shown) used for the storage unit 70 may be selected by estimating the data capacity from the required data storage period.
  • the number of data such as setting the number of numerical data (manufacturing date, time, number of counted pixels) to be large and setting the number of large-capacity image data to be small is set. It can also be changed according to.
  • the notification unit 80 notifies the unit unit identification code and the determination result.
  • a display unit 81 for displaying the unit unit identification code corresponding to the determination result and the determination result is provided.
  • the notification unit 80 causes the screen of the display unit 81 to display whether it is normal or abnormal at an appropriately set timing such as every hour, every hour, every day, or the like. As a result, the operator is notified of the operating status of the machining unit. Alternatively, the trend of the determination result can be displayed in an appropriately set period.
  • a sound output unit (not shown) that notifies an abnormal time by a warning sound or sound together with a screen display.
  • the unit unit identification number corresponding to the determination result and the determination result may be notified by voice.
  • the notification unit 80 may include a printing unit (not shown).
  • the determination result for each unit unit identification code can also be output as a form at an appropriately set timing such as every hour, every day, or every month.
  • control unit 11 has a control unit 90.
  • the control unit 90 can communicate within the control system 10. Therefore, the control part 90 and the test
  • the control unit 90 instructs to change the manufacturing condition of the processing unit 20 or stop the manufacturing line based on the determination result corresponding to the unit unit identification code.
  • the production line includes a discharge unit (not shown) that discharges the workpiece 101 determined as a defective product by the determination unit 50 to the outside of the production line.
  • the control system 10 or the control unit 11 controls the discharge unit based on the pass / fail data received from the determination unit 50. That is, when the pass / fail data is defective, when the defective product passes through the discharge unit, a discharge mechanism (not shown) included in the discharge unit can be operated to discharge the defective product from the production line.
  • Said control system 10 can detect an abnormal location rapidly and correctly. Therefore, it is possible to reduce the time for investigating the processing unit 20 that does not require maintenance among the plurality of processing units 20, and to improve the time productivity of the manufacturing apparatus.
  • a slight difference occurring in a specific unit unit can be captured from the determination result for each unit unit identification number.
  • the operator of the production line can easily adjust the processing conditions and the like for suppressing the variation in the products, and can improve the quality of the workpiece.
  • a production line control device 12 employing the control system 10 includes the above-described plurality of processing units 20 and a control unit 11 that controls the processing units 20.
  • the processing unit 20 has a plurality of unit units 30, and each of the plurality of unit units has a unit unit identification code.
  • the control unit 11 has an inspection unit 40 that inspects the workpiece 101.
  • the inspection unit 40 can communicate with each unit in the control device 12, for example, between the inspection unit 40 and the control unit 90 of the control unit 11 and between the control unit 11 and the processing unit 20.
  • the inspection unit 40 includes the determination unit 50, the data processing unit 60, the storage unit 70, and the notification unit 80 described above.
  • control unit 11 preferably includes a control unit 90 that changes the manufacturing conditions of the processing unit 20 or instructs the stop of the manufacturing line based on the determination result corresponding to the unit unit identification code by the determination unit 50.
  • a method for controlling the production line when producing the workpiece 101 using the production line control system 10 (the production line control device 12) will be described.
  • a unit unit identification code is assigned to each of the plurality of unit units 30 included in the processing unit 20 (step 1). This step 1 makes it easy to specify the unit unit 30 even if there are a plurality of similar unit units 30.
  • the workpiece manufactured by the processing unit 20 is inspected (step 2).
  • the control system 10 performs this process 2 in the inspection unit 40.
  • the image processing unit 43 performs the above-described processing based on the image captured by the imaging unit 41. It is determined whether or not the state of the inspected workpiece is normal, and a determination result is obtained (step 3).
  • an image processing unit 43 performs image processing on a captured image obtained by imaging the workpiece 101 produced by the machining unit 20 with the imaging unit 41.
  • the processing data obtained by the image processing is compared with processing data of a normal product registered in advance, and the state of the workpiece 101 obtained by the processing unit 20 is determined.
  • the determination result is associated with the unit unit identification code of the processing unit 20 that has processed the workpiece 101 determined by the determination unit 50 (step 4).
  • the control system 10 performs the process 4 in the data processing unit 60.
  • each workpiece determined to be normal or abnormal is associated with the unit unit 30 of the unit unit identification code obtained by processing the workpiece.
  • the determination result is memorize
  • the control system 10 performs step 5 in the storage unit 70.
  • the unit unit identification code and the determination result are notified (step 6).
  • the control system 10 performs this step 6 in the notification unit 80.
  • the notification unit 80 displays a unit unit identification code corresponding to the determination result and the determination result.
  • the display method various methods such as displaying on the display unit 81 as described above, notifying by a warning sound or voice, and outputting as a form can be used.
  • the details of the processing unit 20, the unit unit 30, the unit unit identification code, the inspection unit 40, the determination unit 50, the data processing unit 60, the storage unit 70, and the notification unit 80 are as described above.
  • the unit unit identification code and the determination result are transmitted to the control unit 90, and the manufacturing condition of the processing unit 20 is changed or the production line is stopped based on the determination result (particularly the abnormality determination result) corresponding to the unit unit identification code. May be indicated. Further, defective products may be discharged from the production line. In this way, a plurality of processing units 20 can be controlled.
  • the absorbent body manufacturing apparatus 110 supplies an absorbent body material 154 including a fiber material through the duct 130 together with an air flow, and the absorbent body material 154 is disposed on a circumferential surface of the rotary drum 142 of the stacking machine 140 (hereinafter referred to as a product). Also referred to as a concave portion for textiles).
  • the production apparatus 110 includes a pulp feeder 150 that sends out a pulp sheet 151 drawn from a pulp original fabric (not shown), and includes a defibrator 120 that defibrates the pulp sheet 151 and obtains pulp fibers 152. Furthermore, it has the duct 130 used as the path
  • the defibrating machine 120 includes a casing 121 and a rotary blade 122 that is disposed in the casing 121 and scratches the end of the pulp sheet 151 to form a fiber.
  • the casing 121 includes an opening 123 for taking in the pulp sheet 151 and an opening 124 for discharging the pulp fibers 152.
  • the duct 130 has one end 130 a connected to the opening 124 of the defibrator 120 and the other end 130 b covering a part of the outer peripheral surface of the rotating drum 142.
  • the rotating drum 142 has, for example, a plurality of stacking concave portions 141 formed at a predetermined interval on the circumferential surface.
  • the absorbent material 154 (pulp fibers 152, water-absorbing polymer 153) (indicated by arrows for convenience) that has been transported through the duct 130 is supplied toward the circumferential surface of the rotary drum 142, and is supplied to the concave portion 141 for stacking fibers. Is deposited.
  • the absorbent body 105 as the workpiece 101 deposited in the concave portion 141 for fiber pile is used as an absorbent body for absorbent articles such as baby paper diapers, sanitary napkins, incontinence pads, and the like.
  • the shape of the stacking concave portion 141 is determined in accordance with the use of the absorbent body 105.
  • the shape of the fiber stacking concave portion 141 is determined so that a convex portion or a concave portion is formed at a necessary portion of the absorbent body 105.
  • the stacking concave portion 141 is not limited to the above shape, and may have a constant depth, or may be continuously formed along the outer peripheral surface of the rotating drum 142.
  • An intake fan (not shown) is connected to the rotating drum 142, and the space B in the rotating drum 142 is maintained at a negative pressure by driving the intake fan. Due to the negative pressure in the space B, an air flow is generated in the duct 130, and the absorber material 154 from the defibrator 120 is in a scattered state.
  • At least the bottom surface of each of the fiber stacking concave portions 141 is formed of a mesh plate or the like and has a large number of pores. While each of the fiber stacking concave portions 141 passes through the space B maintained at a negative pressure, the pores of the mesh plate function as suction holes.
  • the space B is located at the back side of at least the portion covered with the duct 130 in the rotary drum 142.
  • a strong suction force is generated in the stacking concave portion 141 that passes through the portion covered with the duct 130, thereby depositing the absorbent material 154 in the stacking concave portion 141. Further, an air flow that conveys the absorber material 154 is generated in the duct 130.
  • the space C may be maintained at a negative pressure in order to convey the deposit or absorber while being stably held in the stacking concave portion 141. In this case, the space C has a negative pressure level higher than that of the space B. It may be kept low.
  • the air flow that conveys the absorber material 154 that has flowed through the duct 130 is guided toward the outer peripheral surface of the rotating drum 142 by suction from the fiber-depositing concave portion 141 located on the space B. Furthermore, at the position where the absorbent body 105 is peeled from the fiber stacking concave portion 141, the releasability of the absorbent body 105 may be improved by increasing the pressure in the space D of the rotary drum 142 higher than that of the rotary drum 142.
  • the manufacturing apparatus 110 includes a transport device 170 as a transfer transport mechanism that separates the absorber 105 from the concave portion 141 for stacking fibers and transfers it to the mount 109. As a result, a continuous body 106 having absorbent bodies 105 arranged at equal intervals on the mount 109 is formed.
  • the absorbent material 154 various materials used for absorbent bodies of absorbent articles such as sanitary napkins and disposable diapers can be used without limitation, and at least includes a fiber material.
  • the fiber material for example, short fibers of cellulose fibers such as rayon fibers and cotton fibers, short fibers of synthetic fibers such as polyethylene, and the like can be used in addition to pulp fibers obtained by defibrating a pulp sheet. These fiber materials can be used individually by 1 type or in combination of 2 or more types.
  • a water-absorbing polymer can be further used as the absorber material 154.
  • the absorbent body 105 is formed by being stacked by the stacking machine 140. Thereafter, the absorbent body 105 released from the stacking concave portion 141 of the rotary drum 142 of the stacking machine 140 is placed on the mount 109 and conveyed.
  • the inspection unit 40 of the control unit 11 inspects the shape of the stacked absorbent body 105.
  • the inspection uses the imaging unit 41 and the illumination unit 42 of the inspection unit 40.
  • the imaging unit 41 is disposed above the imaging position of the absorber 105, and the illumination unit 42 is disposed at a position facing the imaging unit 41 with the absorber 105 interposed therebetween.
  • the absorber 105 is irradiated with light from the back surface by the illumination unit 42, and a transmission image of the absorber is captured by the imaging unit 41.
  • the imaging unit 41 may be a camera that can be applied to a manufacturing apparatus.
  • an image processing camera XG-HL02M (trade name: manufactured by Keyence Corporation) can be used.
  • the image processing unit 43 a captured image obtained by the imaging unit 41 binarizes using a binary threshold value T B which is set in advance.
  • the pixels below the binary threshold value T B black, above pixel is converted to white, it counts the number of pixels that have been converted to black.
  • the determination unit 50 determines whether the counted number of black pixels is within the range of the lower limit threshold value TPL and the upper limit threshold value TPH of the preset number of pixels, and the imaged workpiece 101 is normal. It is determined whether or not.
  • the pass / fail data is output to the data processing unit 60.
  • the following method is disclosed as a method for detecting an abnormality of the workpiece 101 (absorber 105).
  • the determination result of each absorber 105 to which the unit unit identification code was given is memorize
  • the determination results from the Nth to the Nmth are stored for each number from the unit unit identification codes 1 to 8.
  • N and m are N> m, and both are natural numbers. This result is shown in a graph of the number of black pixels and the number of determinations with the unit unit identification code as a parameter, as shown in FIG. As can be seen from FIG.
  • the absorber 105 processed by the unit unit 30 (stacking concave portion 141) having the unit unit identification code 3 has a large number of absorbers 105 in which the number of black pixels is smaller than the average number of black pixels.
  • the number of black pixels of a normal unit unit identification code also varies. For example, looking at the (N-1) th data in FIG. 4, the number of pixels of the unit unit identification code 4 having no abnormality is lower than the number of black pixels of the code 3 having abnormality, and is simply the number of black pixels used earlier. It has been found that it is difficult to judge pass / fail with only the threshold values (T PL and T PH ).
  • an average value of the number of black pixels of the absorber 105 can be used. This number is not limited to 20. If the number is large, the accuracy is statistically high, but it is not preferable because it takes too much time to obtain the number of data necessary for determination from the beginning of operation. For example, it is 2 or more, preferably 5 or more, more preferably 10 or more. Moreover, it is 100 or less, Preferably it is 50 or less, More preferably, it is 30 or less.
  • the average value of the number of black pixels of the absorbent body 105 processed by the stacking concave portion 141 of the unit unit identification code 3 is determined by the stacking concave portion 141 of the unit unit identification codes 1 to 8. It was found that the processed absorber 105 was smaller than the total average value of the number of black pixels. This indicates that a minute chip 105h exists in the absorbent body 105 processed by the stacking concave portion 141 of the unit unit identification code 3.
  • Determining unit 50 determines whether the unit unit identification code-specific difference values, are in the range between the lower limit threshold TS PL and upper threshold TS PH preset. The determination result is stored for each unit unit identification code. This storage is performed in the storage unit 70.
  • the difference value for each unit unit identification code is out of the range, it is determined that an abnormality has occurred, and the minute chip occurrence flag and the unit unit identification code of the unit unit 30 in which the minute chip has occurred (concave portion 141 for fiber stacking)
  • the detected information is transmitted to the notification unit 80 and the control unit 90.
  • the notification unit 80 displays whether it is normal or abnormal on the screen of the display unit 81. In the case of an abnormality, a message based on the detection information is displayed, so that the operator can easily know the location where the abnormality has occurred and the content of the abnormality.
  • the control unit 90 can also stop the production line based on the detection information transmitted from the inspection unit 40 when an abnormality occurs continuously for the number of times set in advance by the same unit unit. After the production line is stopped, the operator checks the unit unit 30 in which an abnormality has occurred. For example, when a minute chipping occurs as described above, after stopping the production line, the operator checks the stacking concave portion 141 of the unit unit identification code in which the minute chipping has occurred, and eliminates the cause of the occurrence. Alternatively, the control unit 90 can change the manufacturing condition of the processing unit 20 that needs to be changed. In this way, the control system 10 (control device 12) can quickly detect an abnormal point and accurately remove the abnormality.
  • the basis weight of the absorbent body 105 is abnormal
  • the captured image of the absorber 105 is captured as an image with high gradation by the image processing unit 43.
  • Such an absorber image is imaged brighter than other absorber images.
  • Such bright imaging means that the light transmission amount of the portion is larger than that of the surrounding area, and the basis weight of the absorber 105 is small.
  • the captured image captured by the imaging unit 41 is captured as an image having a gradation different from that of the other normal basis weight captured image of the absorber. .
  • a calibration curve representing the relationship between the basis weight of the absorber 105 and the gradation value is created in advance, and an acceptable gradation value range is determined from the acceptable basis weight range of the absorber 105.
  • the image processing unit 43 sets in advance an inspection region R that covers almost all of the absorber 105, changes the basis weight of the absorber 105, images the absorber 105 by the imaging unit 41, and captures the captured image. obtain.
  • the image processing unit 43 calculates an average gradation value in the region R for each captured image of the captured absorber 105, thereby generating a calibration curve representing the relationship between the basis weight of the absorber 105 and the gradation value.
  • the allowable range of the gradation value (average gradation value) is determined from the allowable basis weight range of the absorber 105.
  • the determination unit 50 determines normal if the average gradation value is within the range of the lower limit threshold value T GL and the upper limit threshold value T GH set in advance, and the basis weight abnormality of the absorber if it is out of the range. Then, the data processing unit 60 causes the storage unit 70 to store the determination result, the basis weight abnormality flag, and the unit unit identification number where the basis weight abnormality has occurred. At the same time, it is transmitted to the notification unit 80 and the control unit 90 as detection information. ⁇ Detection method of slight difference in basis weight> In addition, the following will be disclosed as means for detecting a slight difference in basis weight of the workpiece 101 (absorber 105).
  • the storage unit 70 stores the determination result of each absorber 105 to which the unit unit identification code is assigned for each unit unit identification code.
  • the unit unit identification codes 1 to 8 and the determination results from the Nth to the Nmth are stored for each number.
  • N and m are N> m, and both are natural numbers.
  • This result is shown in the graph of the gradation value and the number of determinations with the unit unit identification code as a parameter, as shown in FIG. From FIG. 6, it was found that the gradation value of the image of the absorber 105 processed by the unit unit 30 (stacking concave portion 141) of the unit unit identification code 2 is higher than the average gradation value.
  • the basis weight of the absorbent body 105 with the unit unit identification code 2 was smaller than that of the absorbent body 105 other than the unit unit identification code 2.
  • Table 2 shows the average value of the gradation values of, for example, 20 absorbers 105 processed by the stacking concave portion 141 of each unit unit identification code.
  • This number is not limited to 20. If the number increases, the accuracy becomes statistically high. However, if the number is too large, it takes time to obtain the number of data necessary for determination from the initial stage of operation. Therefore, it is necessary to consider the number as appropriate. For example, it is 2 or more, preferably 5 or more, more preferably 10 or more. Moreover, it is 100 or less, Preferably it is 50 or less, More preferably, it is 30 or less.
  • the average gradation value of the absorbent body 105 processed by the stacking concave portion 141 having the unit unit identification code 2 was processed by the stacking concave portion 141 having the unit unit identification codes 1 to 8. It was found that the total average gradation value of the absorber 105 was higher. This indicates that the basis weight of the absorbent body 105 processed by the stacking concave portion 141 of the unit unit identification code 2 is reduced. Note that the total average gradation value is an average gradation value of (N ⁇ m) ⁇ 8.
  • the difference between the total average gradation value of the absorber 105 and the average gradation value of the unit unit identification code ([total average gradation value] ⁇ [average gradation value of each unit unit]) Calculate
  • the determination unit 50 determines whether or not the calculated difference value exceeds the lower limit threshold value TS GL and the upper limit threshold value TS GH of the preset difference. If the difference value is outside the threshold range, it is determined that an abnormality has occurred. Then, the data processing unit 60 causes the storage unit 70 to store the determination result, the minute basis weight abnormality flag, and the unit unit identification code of the unit unit 30 in which the minute basis weight abnormality has occurred. At the same time, it is transmitted to the notification unit 80 and the control unit 90 as detection information.
  • the notification unit 80 displays whether it is normal or abnormal on the screen of the display unit 81. Similarly to the above, by displaying a message based on the detection information in the case of an abnormality, the operator can easily know the location of the abnormality and the content of the abnormality.
  • the control unit 90 can change the manufacturing condition of the processing unit 20 that needs to be changed based on the detection information transmitted from the inspection unit 40. For example, when a basis weight abnormality has occurred as described above, for example, by adjusting the air volume at the time of fiber stacking as the production conditions and the feed amount per unit time of the pulp feeder 150, the cause of the occurrence of the basis weight abnormality Eliminate.
  • the control unit 90 can stop the production line. For example, when an abnormality occurs in the unit units 30 having the same unit unit identification code for a preset number of times or more, the control unit 90 stops the production line.
  • control system 10 (control device 12) can quickly detect and restore the abnormal part of the unit unit 30 quickly.
  • the discharge of defective products will be specifically described.
  • FIG. 3 described above consider a case in which a minute chip 105h is generated in the absorber 105 due to a defect in the manufacturing apparatus 110 in the unit unit identification code 3.
  • FIG. 5 described above a case is considered in which the unit unit identification code 2 has a defect in which the basis weight of the absorbent body 105 is small due to a defect in the manufacturing apparatus 110.
  • the inspection unit 40 stores inspection data while sequentially inspecting the workpiece 101 (imaging and image processing). If the inspection result is defective, the controller 90 outputs a defective product signal to a discharge unit (not shown). That is, based on the determination result of the determination unit 50, the control unit 90 operates the discharge unit to discharge defective products from the production line.
  • a unit unit identification code is assigned to each of the plurality of unit units 30 included in the machining unit 20. For this reason, when defects are concentrated on the determination result of a specific unit unit identification code, there is a cause of causing the workpiece 101 to be a defective product in the unit unit 30 to which the unit unit identification code is assigned. Recognize.
  • the precut device cuts an elastic body arranged on a sheet.
  • the elastic body groups 213, 214, and 215 composed of a plurality of elastic bodies sandwiched between two sheets 211 and 212 may be cut (pre-cut) and inspected after cutting.
  • the precut device 221 includes a rotatable precut roll 222, and the precut roll 222 includes precut blades 223, 224, and 225. Further, an anvil roll 226 that is rotatable facing the pre-cut roll 222 is disposed.
  • the imaging unit 41 of the inspection unit 40 that inspects the precut portion is arranged.
  • an illumination unit is disposed at a position facing the imaging unit 41 so as to sandwich the two sheets 211 and 212 therebetween.
  • the quality of the pre-cut portion can be determined by the inspection unit 40 based on the image captured by the imaging unit 41 as described with reference to FIG.
  • the case where the elastic body group 214 between the regions where the leg holes of the absorbent article are formed is pre-cut using the pre-cut blade 224 is considered.
  • the three elastic bodies 226, 227, and 228 of the elastic body group 214 may not be sufficiently cut.
  • the elastic body 226 is not cut, and the elastic bodies 227 and 228 are cut.
  • the precut blade 224 (see FIG. 7) may have a blade spill.
  • the pre-cut roll 222 and the anvil roll 226 are not assembled in parallel.
  • none of the elastic bodies 226, 227, 228 is cut.
  • the determination as to whether or not the cutting is performed as described above sets an inspection region 232 in the imaging region 231 (see FIG. 9A).
  • the image processing unit 43 binarizes the image in the inspection area 232 using a preset binarization threshold value, and converts the elastic bodies 226, 227, and 228 to black.
  • the lengths in the x direction L 226A , L 226B , L 227A , etc. ) in the inspection region 232 for the images of the elastic bodies 226, 227, 228 detected by binarization L227B , L228A , and L228B ).
  • the determination unit 50 determines that the elastic body is not cut and is defective. When the length in the x direction of each elastic body image is less than the reference length, it is determined that the elastic body is normally cut. Then, the data processing unit 60 stores the number of times when a cutting failure has occurred in units of unit unit identification codes and stores them in the storage unit 70. Further, the notification unit 80 informs the operator that the unit unit having a large number of defects will be adjusted. The operator can correct the problem by changing the pressure of the precut device or adjusting the clearance, for example.
  • a strain gauge can be used as a sensor used in the control system 10 (control device 12) of the production line of the present invention.
  • the present invention can be applied to an ultrasonic welding machine 300 as a processing unit 20 in which two pattern anvils 311 and 312 are provided on a pattern roll 310.
  • the ultrasonic welder 300 includes a converter 301, a booster 302, and a horn 303.
  • a pattern roll 310 is provided in which pattern anvils 311 and 312 are sequentially arranged by rotation of the roll at a position facing the horn 303.
  • a unit unit identification code 1 is assigned to the pattern anvil 311, and a unit unit identification code 2 is assigned to the pattern anvil 312.
  • the converter 301 converts ultrasonic waves generated by the ultrasonic oscillator into high-frequency electrical energy, and converts it into mechanical vibration energy using a piezoelectric element.
  • the booster 302 amplifies mechanical vibration energy.
  • the amplified mechanical vibration energy is transmitted to the workpieces 101 and 102 to be welded through the horn 303 which is a resonance body, and the workpieces 101 and 102 are welded to each other.
  • the welding is performed by rubbing the workpieces 101 and 102 with the transmitted vibration energy to generate strong frictional heat at the boundary surface and melting the workpieces 101 and 102. Thereafter, the workpieces 101 and 102 are sent in the direction of arrow D, moved to the next welding position, and the workpieces 101 and 102 are welded again in the same manner as described above.
  • the stress signal of the strain gauge 320 attached to the horn 303 of the ultrasonic welder 300 is input to the determination unit 50 of the inspection unit 40.
  • the strain gauge 320 replaces the imaging unit and the illumination unit of the inspection unit 40.
  • the determination unit 50 determines whether or not there is a pressure difference when processing is performed using the pattern anvils 311 and 312 for each unit unit identification code.
  • the data processing unit 60 associates the determination result obtained by the determination unit 50 with the unit unit identification code of the unit unit 30 (pattern anvils 311 and 312) obtained by processing the determined workpieces 101 and 102.
  • the storage unit 70 stores the determination result for each unit unit identification code.
  • the pressure peaks generated in the pattern anvils 311 and 312 for each unit unit identification code measured by the strain gauge 320 can be compared. If there is a difference in pressure peak between the pattern anvils 311 and 312 to which the unit unit identification codes 1 and 2 are assigned, the clearance adjustment of the pattern anvil is required. Therefore, the display unit 81 of the notification unit 80 prompts the operator to adjust the clearance by displaying the unit unit identification code of the defective pattern anvils 311 and 312 and that there is a pressure abnormality at the time of welding. Examples of the adjustment method include changing the thickness of a shim (not shown) inserted between the pattern roll 310 and the pattern anvils 311 and 312.
  • the production line control system 10 (control device 12) of the present invention can also be applied to the quality determination of each processing unit in an inspection of a semi-finished product processed using a plurality of processing units.
  • the continuous body 106 of the absorber 105 is produced using the manufacturing apparatus 110 (processing unit 20 (also referred to as processing unit 20A)) shown in FIG. Although not shown, the continuous body 106 is cut and formed into individual absorbers 105. Further, as shown in FIG.
  • the absorbent body 105 which is a semi-finished product, is sucked into the absorbent body paste pad 411 by the rotary pasting machine 410 (processing unit 20 ⁇ / b> B), and the direction is rotated by 90 °, It is affixed to the continuous body 401 of the exterior body that is a product. Then, the absorbent body 105 affixed to the exterior body continuum 401 is passed through the leg hole cutter 420 (processing unit 20C), and the outer body continuum 401 is legged by a cutter (not shown) provided in the leg hole cutter 420. A hole 402 (see FIG. 12) is formed.
  • the manufacturing apparatus 110, the rotary pasting machine 410, and the leg hole cutter 420 are arranged in this order, and the imaging unit 41 and the illumination unit 42 of the inspection unit 40 are arranged on the downstream side of the leg hole cutter 420.
  • the inspection unit 40 is the same as that described with reference to FIG.
  • the downstream side refers to the downstream side in the flow direction of the continuous body 401.
  • the manufacturing apparatus 110 (processing unit 20A) shown in FIG. 1 has a unit unit 30 (concave portion 141 for fiber stacking). Although not shown in the figure, for example, unit unit identification codes A1 to A8 (corresponding to unit unit identification codes 1 to 8 in FIG. 1) are assigned to the fiber stacking recesses 141. Further, the rotary pasting machine 410 (processing unit 20B) shown in FIG. 11 has a plurality of unit units 30 (absorber paste pads 411). The absorbent paste pads 411 have unit unit identification codes B1 to B8, for example. Assigned.
  • an image of the workpiece 101 can be obtained by imaging the workpiece 101 using the imaging unit 41.
  • the quality of the workpiece 101 can be determined based on the image obtained by the imaging unit 41.
  • the determination is performed as follows, for example. As shown in FIG. 12, the width direction (CD) of the exterior body continuum 401 enters the captured image 431, and the absorbent body in the machine flow direction (MD) of the exterior body continuum 401 (see FIG. 11). Imaging conditions are set so that one absorbent article (semi-finished product) is placed around 105. Examples of imaging conditions include an angle of view and imaging timing. Therefore, in the normal state, the left half of the leg hole 402 and the right half of the leg hole 403 formed so as to sandwich the attached absorber 105 are captured in the captured image 431.
  • the image processing unit 43 has an inspection area 432a indicated by an arrow for measuring the attachment position in the MD direction (X direction) and an inspection area indicated by an arrow for measuring the attachment position in the CD direction (Y direction) with respect to the captured image 431. 432b is set. Then, edge extraction is performed in the Y direction for the inspection region 432a and in the X direction for the inspection region 432b.
  • the edge extraction process By the edge extraction process, the affixing position D1 in the CD direction of the absorber detected in the inspection region 432a and the affixing position D2 in the MD direction of the absorber detected in the inspection region 432b are measured. In addition, in order to make it easy to see on the drawing, the inspection region 432a and the pasting position 2D are illustrated apart from each other, but the directions are actually coincident.
  • the edge extraction is a process of differentiating the gradation value in the X or Y direction to extract a portion where the change in the gradation value is large, and various other known edge extraction processes can be applied.
  • the unit unit identification code of the affixing pad 411 to which the absorber 105 is affixed corresponds to the distance from the imaging position to the position to which the absorber 105 is affixed. That is, it can be specified by the number of semi-finished products in the MD direction and the rotation angle of the bonding pad 411 when the absorber 105 is bonded. Accordingly, the data processing unit 60 (see FIG. 2) can associate the captured image captured by the image processing unit 43 with the unit unit identification codes B1 to B8 (see FIG. 11). The data processing unit 60 collects the measurement data for each unit unit identification code.
  • the standard deviation of the attachment position of the absorber 105 which is necessary for determining whether the attachment accuracy of the absorber 105 in the rotary applicator 410 (processing unit 20B) is different for each unit unit identification code, is obtained. Each can also be requested.
  • the determination unit 50 can receive the standard deviation of the attachment position by each absorber attachment pad 411 from the data processing unit 60. Then, it is determined whether or not the standard deviation of the attachment position of the absorber 105 for each unit unit identification code is larger than a preset [deviation threshold value]. When the standard deviation of the attachment position of the absorber 105 exceeds the deviation threshold, it is determined that an abnormality has occurred. In this way, in the step of obtaining the determination result by the determination unit 50, the standard deviation is obtained from the data for each unit unit identification code, and abnormality is determined from the standard deviation. Thereafter, the data processing unit 60 stores the determination result, the pasting abnormality flag, and the unit unit identification number in which the pasting abnormality has occurred in the storage unit 70 in association with each other.
  • the notification unit 80 causes the display unit 81 to display a message based on the pasting position abnormality flag and alerts the operator.
  • the controller 90 can also perform control to increase the suction pressure of a suction device (not shown) attached to the absorbent body attachment pad 411, for example, in order to reduce variations in the attachment position of the absorbent body 105.
  • the control unit 90 stops the production line.
  • a signal indicating that the suction pressure has exceeded the allowable value and a unit unit identification code of the absorber pasting pad 411 having an abnormality are transmitted to the notification unit 80.
  • the notification unit 80 displays a message according to the content on the display unit 81 and prompts the operator to check. With the above operation, the attaching accuracy of the absorber 105 can be improved.
  • the imaged image is provided with an inspection region (not shown) in the absorber 105, and binarized to detect minute chips, as described with reference to FIGS. can do.
  • the basis weight abnormality of the absorber 105 can be detected by obtaining the gradation value of the absorber 105.
  • the detection of minute chips and the detection of basis weight abnormality may be performed as described above.
  • the storage unit 70 stores determination results for each of the unit unit identification codes A1 to A8 and B1 to B8.
  • the notification unit 80 notifies the unit unit identification code and the determination result.
  • the display unit 81 displays the unit unit identification code corresponding to the determination result and the determination result.
  • the unit unit identification codes A1 to A8 and B1 to B8 if the determination result corresponding to a certain unit unit identification code exceeds the threshold value, the unit unit It is determined that there is an abnormality in the unit unit 30 of the identification code. In this way, even if the single workpiece 101 is imaged only once by the single imaging unit 41, the unit units 30 of the plurality of machining units 20 can be inspected simultaneously.
  • the present invention further discloses the following embodiments.
  • a production line control system including a processing unit for obtaining a workpiece, The control system includes the processing unit and a control unit that controls the processing unit, The processing unit has a plurality of unit units, Each of the plurality of unit units has a unit unit identification code, The production line control system has an inspection unit for inspecting the workpiece, The inspection unit can communicate within the control system of the production line, The inspection unit includes a determination unit that determines a state of the workpiece and obtains a determination result, the determination result, and the unit unit identification code of the processing unit that has processed the workpiece that has performed the determination.
  • a production line control system comprising: a data processing unit that associates the unit unit identification code; a storage unit that stores the determination result for each unit unit identification code; and a notification unit that notifies the unit unit identification code and the determination result.
  • the inspection unit includes an imaging unit that images a workpiece by the processing unit, and an image processing unit that processes a captured image obtained by the imaging unit,
  • the determination unit is described in ⁇ 1>, in which a state of a workpiece obtained by the machining unit is determined by comparing the machining data obtained by the image processing unit with the machining data of a normal product registered in advance.
  • Production line control system ⁇ 3> The production system according to ⁇ 2>, wherein the imaging unit captures a transmission image of the absorber.
  • the image processing unit binarizes the captured image obtained by the imaging unit using a preset binarization threshold value. .
  • the image processing unit creates in advance a calibration curve representing the relationship between the basis weight of the absorber and the gradation value from the captured image of the absorber, and has an acceptable gradation value from the range of the acceptable basis weight of the absorber.
  • the production line control system according to any one of ⁇ 2> to ⁇ 4>, wherein the range is determined.
  • ⁇ 6> The production line control system according to any one of ⁇ 1> to ⁇ 5>, wherein the notification unit includes a display unit on which the unit unit identification code corresponding to the determination result and the determination result are displayed.
  • ⁇ 7> The production line control system according to any one of ⁇ 1> to ⁇ 6>, wherein the notification unit is a voice output unit that reports the unit unit identification code according to the determination result and the determination result by voice.
  • the data processing unit obtains a standard deviation from the data for each unit unit identification code and transmits the standard deviation to the determination unit, and the determination unit determines any abnormality from the standard deviation ⁇ 1> to ⁇ 7>
  • the manufacturing line control system has a control unit that changes manufacturing conditions of the processing unit based on a determination result corresponding to the unit unit identification code, or stops the manufacturing line.
  • the production line control system according to any one of ⁇ 1> to ⁇ 8>, wherein the control unit is capable of communicating within the production line control system.
  • the determination unit the pixel below the binary threshold value T B black, above pixel is converted to white, counts the number of pixels that have been converted to black, the counted number of black pixels is the number of pixels preset It is determined whether it is within the range of the lower threshold TPL and the upper threshold TPH , it is determined whether the imaged workpiece is normal, and pass / fail data is output to the controller ⁇ 9> The production line control system described in 1.
  • the production line includes a discharge unit, The production line control system according to any one of ⁇ 1> to ⁇ 10>, wherein the production line control system operates the discharge unit based on the determination result.
  • the production line includes a plurality of the processing units having different functions, The processing unit has the plurality of unit units, Each of the plurality of unit units has a unit unit identification code; The production line control system according to any one of ⁇ 1> to ⁇ 11>, wherein the inspection unit that inspects the workpiece that has been processed by the plurality of processing units is disposed.
  • the production line control system according to any one of ⁇ 1> to ⁇ 12>, wherein the processing unit is an absorber manufacturing apparatus.
  • ⁇ 14> The manufacturing system of the absorbent body according to ⁇ 13>, wherein the absorbent body manufacturing apparatus is configured to deposit an absorbent body material including a fiber material in a stacking recess of a stacking machine.
  • ⁇ 15> ⁇ 14>
  • ⁇ 16> The production unit control system according to ⁇ 14> or ⁇ 15>, wherein the unit unit is a plurality of concave portions for stacking in the stacking machine of the absorbent body manufacturing apparatus.
  • the data processing unit calculates the total average value of black pixels ((N ⁇ m) ⁇ n), calculates the average number of black pixels for each unit unit identification code, and calculates the total average value of black pixels. And the difference between the average value of each unit unit identification code ([total average value]-[average value of each unit unit]), The determination unit determines whether the difference value for each unit unit identification code is within a range between a preset lower threshold TSPL and an upper threshold TSPH , any one of ⁇ 1> to ⁇ 16> 2.
  • TSPL lower threshold
  • TSPH upper threshold
  • the determination unit determines normal if the average gradation value is within the range of the lower limit threshold T GL and the upper limit threshold T GH set in advance, and determines that the basis weight abnormality of the absorber is outside the range ⁇
  • the production line control system according to any one of 1> to ⁇ 17>.
  • the data processing unit calculates a difference between the total average value of the gradation values of the absorber and the average value of the gradation values of the unit unit identification code ([total average value] ⁇ [average gradation value of each unit unit]).
  • the determination unit either the calculated difference value is intended to determine whether it exceeds the lower limit threshold TS GL and upper threshold TS GH difference set in advance ⁇ 1> to the ⁇ 18> 1
  • the control unit is configured to change a manufacturing condition of the processing unit that requires a change in manufacturing conditions based on the detection information transmitted from the inspection unit.
  • the processing unit includes a rotary pasting machine that cuts the continuous body of the absorbent body, rotates the individually formed absorbent body by 90 °, and pastes it on the continuous body of the outer body that is a semi-finished product.
  • the production line control system according to any one of ⁇ 1> to ⁇ 20>.
  • a control device for a production line including a processing unit for obtaining a workpiece,
  • the control device includes the processing unit and a control unit that controls the processing unit,
  • the processing unit has a plurality of unit units, Each of the plurality of unit units has a unit unit identification code
  • the control unit has an inspection unit for inspecting a workpiece obtained by the processing unit,
  • the inspection unit can communicate within the control device,
  • the inspection unit is configured to determine a state of the workpiece and obtain a determination result; the determination result; and the unit unit identification code of the processing unit in which the workpiece that has performed the determination is processed.
  • a control apparatus for a production line comprising: a data processing unit that associates the unit unit identification code; a storage unit that stores the determination result for each unit unit identification code; and a notification unit that notifies the unit unit identification code and the determination result.
  • the inspection unit includes an imaging unit that images a workpiece by the processing unit, and an image processing unit that processes a captured image obtained by the imaging unit,
  • the determination unit is described in ⁇ 22>, in which a state of a workpiece obtained by the machining unit is determined by comparing the machining data obtained by the image processing unit with the machining data of a normal product registered in advance.
  • Production line control device. ⁇ 24> The manufacturing device according to ⁇ 23>, wherein the imaging unit captures a transmission image of the absorber.
  • the image processing unit binarizes the captured image obtained by the imaging unit using a preset binarization threshold value. .
  • the image processing unit creates in advance a calibration curve representing the relationship between the basis weight of the absorber and the gradation value from the captured image of the absorber, and has an acceptable gradation value from the range of the acceptable basis weight of the absorber.
  • the production line control device according to any one of ⁇ 23> to ⁇ 25>, wherein the range is determined.
  • the notification unit includes a display unit that displays the unit unit identification code corresponding to the determination result and the determination result.
  • ⁇ 28> The production line control device according to any one of ⁇ 22> to ⁇ 27>, wherein the notification unit is a voice output unit that reports the unit unit identification code according to the determination result and the determination result by voice.
  • the data processing unit obtains a standard deviation from data for each unit unit identification code and transmits the standard deviation to the determination unit, and the determination unit determines any abnormality from the standard deviation ⁇ 22> to ⁇ 28>.
  • the production line control device described in 1. ⁇ 30> The control device of the manufacturing line has a control unit that changes manufacturing conditions of the processing unit based on a determination result corresponding to the unit unit identification code, or stops the manufacturing line.
  • the control device for a production line according to any one of ⁇ 22> to ⁇ 29>, wherein the control unit can communicate within the control device for the production line.
  • the determination unit the pixel below the binary threshold value T B black, above pixel is converted to white, counts the number of pixels that have been converted to black, the counted number of black pixels is the number of pixels preset It is determined whether it is within the range of the lower threshold TPL and the upper threshold TPH , it is determined whether the imaged workpiece is normal, and pass / fail data is output to the controller ⁇ 30>.
  • the production line includes a discharge unit, The production line control device according to any one of ⁇ 22> to ⁇ 31>, wherein the production line control device operates the discharge unit based on the determination result.
  • the production line includes a plurality of the processing units having different functions, The processing unit has the plurality of unit units, Each of the plurality of unit units has a unit unit identification code; The production line control device according to any one of ⁇ 22> to ⁇ 32>, wherein the inspection unit that inspects the workpiece that has been processed by the plurality of processing units is disposed.
  • the production line control apparatus according to any one of ⁇ 22> to ⁇ 33>, wherein the processing unit is an absorbent body production apparatus.
  • ⁇ 35> The production apparatus for an absorbent body according to ⁇ 34>, wherein the production apparatus for the absorbent body deposits an absorbent material containing a fiber material in a stacking recess of the stacking machine.
  • the said processed material is a control apparatus of the manufacturing line as described in ⁇ 35> which is the absorber accumulated in the said recessed part for fiber piles.
  • ⁇ 37> The production unit control device according to ⁇ 35> or ⁇ 36>, wherein the unit unit is a plurality of stacking recesses in the stacking machine of the absorber manufacturing apparatus.
  • the data processing unit calculates the total average value of black pixels ((N ⁇ m) ⁇ n), calculates the average number of black pixels for each unit unit identification code, and calculates the total average value of black pixels. And the difference between the average value of each unit unit identification code ([total average value]-[average value of each unit unit]), The determination unit determines whether the difference value for each unit unit identification code is in a range between a preset lower threshold TSPL and an upper threshold TS PH , any one of ⁇ 22> to ⁇ 37> 2.
  • a control apparatus for a production line according to 1.
  • the determination unit determines normal if the average gradation value is within the range of the lower limit threshold T GL and the upper limit threshold T GH set in advance, and determines that the basis weight abnormality of the absorber is outside the range ⁇ 22.
  • the production line control device according to any one of 22> to ⁇ 38>.
  • the data processing unit calculates a difference between the total average value of the gradation values of the absorber and the average value of the gradation values of the unit unit identification code ([total average value] ⁇ [average gradation value of each unit unit]). )
  • the determination unit determines whether or not the calculated difference value exceeds a lower limit threshold value TS GL and an upper limit threshold value TS GH that are set in advance.
  • the production line control device described in 1. ⁇ 41> The control unit is configured to change the manufacturing condition of the processing unit that requires a change in manufacturing conditions based on the detection information transmitted from the inspection unit. ⁇ 22> to ⁇ 40> Control device. ⁇ 42> The processing unit includes a rotary pasting machine that cuts the continuous body of the absorbent body, rotates the individually formed absorbent body by 90 °, and pastes it on the continuous body of the outer body that is a semi-finished product. ⁇ 22> to ⁇ 41>, the production line control device according to any one of ⁇ 22> to ⁇ 41>.
  • a method for controlling a production line comprising a plurality of processing units for producing a workpiece, Giving a unit unit identification code to each of the plurality of unit units of the processing unit; Inspecting the fabricated workpiece, Determining the state of the inspected workpiece and obtaining a determination result; Associating the determination result with the unit unit identification code of the processing unit that has processed the workpiece subjected to the determination; Storing the determination result for each unit unit identification code; A method for controlling a production line, comprising the step of notifying the unit unit identification code and the determination result.
  • a captured image obtained by capturing an image of the workpiece produced by the processing unit by the image capturing unit is subjected to image processing by the image processing unit, and processed data obtained by the image processing and registered in advance
  • the manufacturing line control method according to ⁇ 43> wherein the state of the workpiece obtained by the processing unit is determined by comparing the processed data of the normal product.
  • the workpiece is an absorber;
  • the image processing unit creates in advance a calibration curve representing the relationship between the basis weight of the absorber and the gradation value from the captured image of the absorber, and the gradation that is acceptable from the range of the acceptable basis weight of the absorber.
  • ⁇ 48> The method of controlling a production line according to any one of ⁇ 43> to ⁇ 47>, wherein in the notifying step, the unit unit identification code corresponding to the determination result and the determination result are displayed.
  • ⁇ 49> The method of controlling a production line according to any one of ⁇ 43> to ⁇ 48>, wherein in the notifying step, the unit unit identification code corresponding to the determination result and the determination result are notified by voice.
  • ⁇ 50> The method for controlling a production line according to any one of ⁇ 43> to ⁇ 49>, wherein in the step of obtaining the determination result, a standard deviation is obtained from data for each unit unit identification code, and an abnormality is determined from the standard deviation .
  • ⁇ 51> The manufacturing line control method according to any one of ⁇ 43> to ⁇ 50>, wherein the manufacturing condition of the processing unit is changed or the manufacturing line is stopped based on a determination result corresponding to the unit unit identification code. .
  • ⁇ 52> The method of controlling a production line according to any one of ⁇ 43> to ⁇ 51>, wherein defective products are discharged from the production line based on the determination result.
  • ⁇ 53> The method for controlling a production line according to any one of ⁇ 43> to ⁇ 52>, wherein the plurality of processing units are controlled.
  • ⁇ 54> The method for controlling a production line according to any one of ⁇ 43> to ⁇ 53>, wherein the processing unit is an absorber production apparatus.
  • ⁇ 55> The production apparatus for controlling a production line according to ⁇ 54>, wherein the absorbent body manufacturing apparatus deposits an absorbent material containing a fiber material in a stacking recess of a stacking machine.
  • ⁇ 56> The method for controlling a production line according to ⁇ 55>, wherein the workpiece is an absorbent body deposited in the concave portion for stacking fibers.
  • ⁇ 57> The production unit control method according to ⁇ 55> or ⁇ 56>, wherein the unit unit is a plurality of concave portions for stacking in the stacking machine of the absorbent body manufacturing apparatus.
  • Control unit 10 Control system of production line 11 Control unit 12 Control apparatus 20, 20A, 20B, 20C Processing unit 30 Unit unit 40 Inspection part 41 Imaging part 42 Illumination part 43 Image processing part 50 Determination part 60 Data processing part 70 Storage part 80 Notification part 81 Display unit 90 Control unit 101, 102 Work piece 105 Absorber 105h Minute chip 106 Continuous body 109 Mount 110 Production apparatus 120 Defibrator 121 Casing 122 Rotary blade 123, 124 Opening 130 Duct 130a One end part 130b Other end part 140 Stack Textile machine 141 Concave part for fiber pile 142 Rotating drum 150 Pulp feeder 151 Pulp sheet 152 Pulp fiber 153 Water-absorbing polymer 154 Absorber material 170 Conveying device 211, 212 Sheet 213, 214, 215 Elastic body group 221 Precut device 222 Precut roll 223, 224, 225 Precut blade 226 Anvil roll 226, 227, 228 Elastic body 226A, 226B, 228A, 228

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Abstract

L'invention concerne un système de contrôle (10) de ligne de fabrication, comprenant une unité de traitement (20) à partir de laquelle un article traité (101) est obtenu. Ledit système de contrôle (10) comprend l'unité de traitement (20) et une unité de contrôle (11) qui contrôle l'unité de traitement (20). L'unité de traitement (20) comprend en outre une pluralité d'unités individuelles (30). Chaque unité de la pluralité d'unités individuelles (30) comprend en outre un symbole d'identification (1-8) d'unité individuelle. Le système de contrôle (10) de ligne de fabrication comprend en outre une unité d'inspection (40) qui inspecte l'article traité (101). L'unité d'inspection (40) est capable de communication dans le système de contrôle (10) de ligne de fabrication. L'unité d'inspection (40) comprend en outre : une unité d'estimation (50) dans laquelle est faite une estimation de l'état de l'article traité (101) et dans laquelle est obtenu un résultat d'estimation ; une unité de traitement de données (60) qui associe le résultat d'estimation au symbole d'identification (1-8) d'unité individuelle qui est compris par l'unité de traitement (20) à partir de laquelle a été obtenu l'article traité (101) sur lequel l'estimation a été effectuée ; une unité d'enregistrement (70) dans laquelle les résultats d'estimation sont enregistrés pour chacun des symboles d'identification (1-8) d'unités individuelles ; et une unité de notification (80) par laquelle est émise une notification des symboles d'identification (1-8) d'unités individuelles et des résultats d'estimation.
PCT/JP2017/043265 2016-12-02 2017-12-01 Système de contrôle de ligne de fabrication, dispositif de contrôle de ligne de fabrication, et procédé de contrôle de ligne de fabrication WO2018101457A1 (fr)

Priority Applications (3)

Application Number Priority Date Filing Date Title
CN201780066120.3A CN109891343A (zh) 2016-12-02 2017-12-01 生产线的控制系统、生产线的控制装置和生产线的控制方法
US16/347,487 US20190282408A1 (en) 2016-12-02 2017-12-01 Control system of production line
EP17876995.6A EP3550390A4 (fr) 2016-12-02 2017-12-01 Système de contrôle de ligne de fabrication, dispositif de contrôle de ligne de fabrication, et procédé de contrôle de ligne de fabrication

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JP2016235063 2016-12-02
JP2016-235063 2016-12-02
JP2017226718A JP6587671B2 (ja) 2016-12-02 2017-11-27 製造ラインの制御システム、製造ラインの制御装置、及び製造ラインの制御方法
JP2017-226718 2017-11-27

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JP2013013523A (ja) * 2011-07-01 2013-01-24 Unicharm Corp 不良検出システム及び不良検出方法
JP2014507233A (ja) * 2011-02-24 2014-03-27 ジーディーエム エス．ピー．エー． 乳児用オムツまたは大人用失禁パッド、生理用ナプキンなどの、吸収性衛生用品の生産ラインの作業に対する是正動作のための方法
US20150066187A1 (en) * 2013-09-03 2015-03-05 The Procter & Gamble Company Systems and Methods for Adjusting Target Manufacturing Parameters on an Absorbent Product Converting Line
JP2015142084A (ja) * 2014-01-30 2015-08-03 オムロン株式会社 品質管理装置、品質管理方法

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JP2014507233A (ja) * 2011-02-24 2014-03-27 ジーディーエム エス．ピー．エー． 乳児用オムツまたは大人用失禁パッド、生理用ナプキンなどの、吸収性衛生用品の生産ラインの作業に対する是正動作のための方法
JP2013013523A (ja) * 2011-07-01 2013-01-24 Unicharm Corp 不良検出システム及び不良検出方法
US20150066187A1 (en) * 2013-09-03 2015-03-05 The Procter & Gamble Company Systems and Methods for Adjusting Target Manufacturing Parameters on an Absorbent Product Converting Line
JP2015142084A (ja) * 2014-01-30 2015-08-03 オムロン株式会社 品質管理装置、品質管理方法

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