Abstract:
Techniques are described for inspecting a web and controlling subsequent conversion of the web into one or more products. A system, for example, comprises an imaging device, an analysis computer and a conversion control system. The imaging device images the web to provide digital information. The analysis computer processes the digital information to identify regions on the web containing anomalies. The conversion control system subsequently analyzes the digital information to determine which anomalies represent actual defects for a plurality of different products. The conversion control system determines a value for at least one product selection parameter for each of the products, and selects one of the products for conversion of the web based on the respective determined value. Exemplary product selection parameters include web utilization, unit product produced, estimated revenue or profit, process time, machine capacity and demand for the different products.
Abstract:
A conversion control system is described that includes a database to store data defining a set of rules and an interface to receive local anomaly information from a plurality of different analysis machines associated with a plurality of manufacturing process lines that perform a plurality of operations on a web of material, and each of the manufacturing process lines includes position data for a set of regions on the web containing anomalies. The system also includes a computer that registers the position data of the local anomaly information for the plurality of manufacturing process lines to produce aggregate anomaly information. The system further includes a conversion control engine that applies the rules to the aggregate anomaly information to determine which anomalies represent actual defects in the web for a plurality of different products.
Abstract:
A system for preferentially marking defects on a web is described. The system includes a web of material to be converted into individual sheets of a plurality of different grade levels, a database storing anomaly data of anomalies on the web, wherein an anomaly is a potential defect in at least one of the plurality of different grade levels, a marker that associates a unique mark with at least one of the grade levels, and a controller to retrieve the anomaly data from the database and to signal the marker as to where to make a mark, wherein the marker applies the mark associated with at least one of the grade levels for which the anomaly may cause a defect. The system may provide advantages, such as that a converter of various products from a single web roll may determine which regions of the web satisfy each grade level
Abstract:
A device for applying fiducial marks to a web for spatially synchronizing data from a plurality of processes is described. The device includes a fiducial mark reader to read fiducial marks of at least two formats on a web of material, a fiducial mark writer to write fiducial marks of at least two formats on the web, and an encoder to measure distance along the web. The device may provide several advantages. For example, the device may apply fiducial marks to a web that indicate the process line that applied the fiducial mark to the web or the date on which the fiducial mark was applied.
Abstract:
Techniques are described for inspecting a web and controlling subsequent conversion of the web into one or more products. A system, for example, includes an imaging device, an analysis computer and a conversion control system. The imaging device images a sequential portion of a web to provide digital information. The analysis computer processes the digital information with an initial algorithm to identify regions on the web containing anomalies. The conversion control system selects one of a plurality of converting sites to convert the web into a product, and analyzes at least a portion of the digital information with at least one subsequent algorithm to determine which anomalies represent actual defects in the web for the products.
Abstract:
An imaging device for sequentially imaging a portion of a continuously moving web (10) to provide a digital data stream which is then analyzed by a single computer (18) without the used of dedicated signal processing hardware. Techniques for operating on the data stream from an imaging device are disclosed, particularly including operations based on blob information stored in terms of starting position and segment run lengths in a cross-web direction. These allow definitions of blobs to be accumulated in a line-by-line fashion, and allow classes of defects commonly found in continuous web manufacturing to be identified with far less computing power than was previously required. In particular, in the challenging application of inspecting flexible circuits, data rates in excess of 10 mega-pixels/second are achieved and successfully processed.