System and method for determining an impact of manufacturing processes on the caliper of a sheet material

• US 10,184,897 B2
• Filed: 03/19/2018
• Issued: 01/22/2019
• Est. Priority Date: 04/04/2014
• Status: Active Grant

• Current Assignee: Packaging Corporation of America
• Original Assignee: Packaging Corporation of America
• Inventors: Frank, Benjamin
• Primary Examiner(s): Patel, Jayanti K
• Assistant Examiner(s): Habib, Irfan
• Application Number:
  US15/924,677
• Publication Number:
  US 20180209914A1
• Time in Patent Office: 309 Days
• CPC Class Codes: B31F 1/2831 Control
• CPC Class Codes: B65H 7/14 by photoelectric feelers or detectors
• CPC Class Codes: B65H 7/20 Controlling associated apparatus
• CPC Class Codes: G01N 21/86 Investigating moving sheets G01N21/89 takes precedence
• CPC Class Codes: G01N 21/8803 Visual inspection measuring projectors G01B9/08
• CPC Class Codes: G06T 2207/10016 Video; Image sequence
• CPC Class Codes: G06T 2207/30164 Workpiece; Machine component
• CPC Class Codes: G06T 7/001 using an image reference approach

Abstract

A method for processing a plurality of sheet material includes receiving a plurality of sheets of material, transporting, via a transport mechanism, the plurality of sheets, one sheet at a time, past a first image capture device, obtaining, via a first image capture device, a first image of a first set of one or more of the plurality of sheets while being transported past the first image capture device, and determining, via at least one processor, a first caliper measurement of the first set of one or more of the plurality of sheets based on the first image of each of the first set.

Claims

1. A system for processing a plurality of sheets of material, the system comprising:

an input configured to receive the plurality of sheets of material;

an output;

a transport mechanism configured to transport the plurality of sheets of material, one sheet at a time, from the input along a transport path to the output;

a manufacturing process device disposed along the transport path and configured to change each of the plurality of sheets of material from a first state to a second state;

a first image capture device configured to obtain one or more first images, each of the one or more first images being of at least one of the plurality of sheets of material; and

at least one processor communicatively coupled to the first image capture device, the at least one processor being configured to determine process-impact information based on the one or more first images, the process-impact information including at least a caliper measurement of each of the at least one of the plurality of sheets of material wherein a change in caliper is determined by the difference between the first caliper measurement of each of the at least one of the plurality of sheets of material and a second caliper measurement.

2. The system of claim 1, wherein the at least one processor is further configured to determine whether an error condition exists based on the process-impact information and one or more error checking criteria.

3. The system of claim 1, wherein the first image capture device is positioned adjacent the transport mechanism along the transport path and oriented such that each of the first images includes a lateral side of each of the plurality of sheets of material.

4. The system of claim 1, wherein the first image capture device is positioned adjacent the transport mechanism generally orthogonal to the transport path.

5. The system of claim 1, wherein the plurality of sheets of material comprises corrugated fiberboard.

6. The system of claim 1, wherein the process-impact information is determined by the at least one processor, at least in part, by comparing the one or more first images of the first image capture device with a previously measured set of satisfactory caliper measurements.

7. A method for processing sheet material, the method comprising:

receiving a plurality of sheets of material;

transporting, via a transport mechanism, the plurality of sheets of material, one sheet at a time, past a first image capture device;

obtaining, via the first image capture device, one or more first images of a first set of one or more of the plurality of sheets of material while the plurality of sheets of material is transported past the first image capture device one sheet at a time;

determining, via at least one processor, a first caliper measurement of the first set of one or more of the plurality of sheets of material based on the one or more first images of the first set; and

determining a change in caliper is determined by the difference between the first caliper measurement of each of the at least one of the plurality of sheets of material and a second caliper measurement.

8. The method of claim 7, further including determining whether an error condition exists based on the process-impact information and one or more error checking criteria.

9. The method of claim 7, wherein the first image capture device is positioned adjacent the transport mechanism along the transport path and oriented such that each of the first images includes a lateral side of each of the plurality of sheets of material.

10. The method of claim 7, wherein the first image capture device is positioned adjacent the transport mechanism generally orthogonal to the transport path.

11. The method of claim 7, wherein the plurality of sheets of material comprises corrugated fiberboard.

12. The method of claim 7, further including determining process-impact information by the at least one processor, at least in part, by comparing the one or more first images of the first image capture device with a previously measured set of satisfactory caliper measurements.