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

• US 9,952,160 B2
• Filed: 04/02/2015
• Issued: 04/24/2018
• 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:
  US14/677,316
• Publication Number:
  US 20150285742A1
• Time in Patent Office: 1,118 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;

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; and

a second image capture device configured to obtain one or more second images each of the one or more second images being of the at least one of the plurality of sheets of material the process-impact information being further based on the one or more second images,

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

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 process-impact information includes one or more changes in caliper measurements based on the one or more first images and the one or more second images.

6. The system of claim 1, wherein the one or more sheets comprise corrugated fiberboard.

7. 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.

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

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

an output receptacle configured to receive at least some of the plurality of sheets of material;

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

a manufacturing process device disposed along the transport path and configured to apply a manufacturing process to the plurality of sheets of material;

a first image capture device located at or between the input receptacle and the manufacturing process device, the first image capture device being configured to obtain a first image of a first set of the plurality of sheets of material;

a second image capture device located at or between the manufacturing process device and the output receptacle, the second image capture device being configured to obtain a second image of a second set of the plurality of sheets of material; and

at least one processor communicatively coupled to the first image capture device and the second image capture device, the at least one processor being configured to determine a first caliper measurement for each sheet in the first set of the sheets based on the first images and determine a second caliper measurement for each sheet in the second set of the sheets based on the second images,

wherein the first set of sheets is the same as the second set of sheets the change in caliper being determined by the difference between the first caliper measurement and the corresponding second caliper measurement for each sheet of the first and second sets of the plurality of sheets of material.

9. The system of claim 8, wherein the at least one processor is further configured to determine a change in caliper based on the first caliper measurement and the second caliper measurement.

10. The system of claim 8, wherein the at least one processor is further configured to determine an average change in caliper based on a plurality of first caliper measurements and a plurality of second caliper measurements.

11. The system of claim 8, wherein the first set of the sheets and the second set of the sheets include all of the plurality of sheets.

12. The system of claim 8, wherein each of the sheets comprises corrugated fiberboard.

13. 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 and a second 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;

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

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 the change in caliper by the difference between the first caliper measurement and the corresponding second caliper measurement for each sheet of the first and second sets of sheets of material.

14. The method of claim 13, further comprising:

processing the plurality of sheets of material to change each of the sheets from a first state to a second state after obtaining the first image;

after being processed, transporting the plurality of sheets of material, one sheet at a time, past a second image capture device;

obtaining, via the second image capture device, one or more second images of a second set of one or more of the plurality of sheets of material while the plurality of sheets of material are transported past the second image capture device; and

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

15. The method of claim 13, further comprising comparing the first caliper measurement and the second caliper measurement to error checking criteria, and generating an error signal based on the comparison.

16. The method of claim 15, wherein the error checking criteria includes one or more tolerance ranges.

17. The method of claim 14, further comprising determining a change in caliper measurement based on the first image and the second image.