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WEB BASED MANUFACTURING

Project Submitted to the JRN Rajasthan Vidyapeeth University in partial fulfillment of therequirements for the award of the Degree of

Diploma in Engineering

Submitted by;

KOSAL RAM(Registration Number)

Project Guide

(BALAKUMAR.P)

JRN RAJASTHAN VIDYAPEETH UNIVERSITY

UDAIPUR

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JRN RAJASTHAN VIDYAPEETH UNIVERSITY

UDAIPUR

Diploma Engg.

BONAFIDE CERTIFICATEREGISTRATION NUMBER:

DE-II/09/231391

Certified that this is the Bonafide record of work done by Mr. Kosal Ram of the RVD UniversityDiploma Engg. during the year 2013.

Project Guide Coordinator

Date:

Examiner

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DECLARATION

I hereby declare that the project entitled Web Based Manufacturing submitted for the

Diploma Engineering is my original work and the dissertation has not formed the basis for the

award of any degree, associate ship, fellowship or any other similar titles.

Place: Kosal Ram

Date: Signature of the Student

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CERTIFICATE

This is to certify that the project entitled Web Based Manufacturing is the bonafideresearch work carried out by Mr. Kosal Ram student of Diploma, JRN Rajasthan Vidyepeeth

University, Udaipur, during the year 2010-2013 in partial fulfillment of the requirements for the awardof the Degree of Diploma Engineering and that the project has not formed the basis for the award

previously of any degree, diploma, associateship, fellowship or any other similar title.

Place: (Guide Name)

Date: Signature of the Guide

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Organizations Letter

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Acknowledgements

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Contents

S.No DESCRIPTION PAGE NO

1.1 Introduction 9-10

2.1 Project objectives 12-13

3.1 Research methodology 15-17

4.1 Concept 18-19

4.2 Need for the study 20-214.3 Problem 21-22

4.4 Objectives 23-24

4.5 Procedure methodology 24-28

5.1 Analysis of the situation 29-36

5.2 Existing system 37-41

5.3 Need For Change in the system 42-47

5.4 Proposed system 48-52

6.1 Designs principles & explanation 53-99

7.1 Summary of the system 99-100

7.2 Scope of the system 100-101

7.3 Suggestion 101-102

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CHAPTER 1

INTRODUCTION

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This paper provides a demonstration of harnessing the power of the Internet to enable

collaborative manufacturing in such a setup where the key components such as the human

resource personnel and the manufacturing equipment are geographically separated. As part of the

framework a platform independent and cost-effective means of remotely operating a 3-axis

computer numerical control (CNC) drilling machine securely via the Internet has been

developed. In addition, an infrastructure to allow remote manufacturers to collaborate on a

product design as well to monitor the drilling process in real time is presented.

The framework rests on sound security foundation implemented using

technologies such as firewall, authentication modules and transport layer security (TLS) protocol

to promote safe usage of the drilling machine. It is worth mentioning that the architectural design

is generic and modular in nature and as such, any other genre of CNC machine such as milling

and turning could be substituted in place of drilling with only machine-specific changes to the

existing system.

Keywords: Virtual enterprise; Collaborative manufacturing; Web-based distributed system; CNCmachine; Remote control; Security

M1 by B&G is an enterprise resource planning (ERP) software system designed for small to

medium manufacturers including job shops, custom and mixed mode manufacturers and makes

to order manufacturers. M1 by B&G provides total integration and automation from quoting

through invoicing and is capable of flexible and fully supported customization that ensures

youre most valuable & unique business processes can be handled with ease.

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Billing System Integration

CRM Integration

Custom User Interface

Customizable Fields

Customizable Functionality

Customizable Reporting

Data Import/Export

Document Management

ERP Integration

Financial Integration

Forecasting

Mobile Access

Multi-Currency

Quality ManagementQuote Management

Reporting

Resource Management

Supplier Management

Supply Chain Management

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CHAPTER - 2Project Objectives

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Customer self-service is a proven contributor to cost savings in financial services organizations.

Your customers expect secure access around the clock to their entire portfolio without the need

to interact with your employees. However, as a financial services organization, you will need to

ensure that this is done safely and securely, which can often be a challenge when faced with

legacy systems and the pressure of cost reductions.

Although Web-based applications are numerous, the complexity and interconnectedness of the

web and web 2.0 poses significant challenges. Management wants to increase the breadth of

customer interaction while at the same time control the risks and ensure high levels of security,

accessibility, compliance and privacy. Most organizations find achieving the balance between

the needs of the business and the constrains of IT is the real challenge.

So how can you ensure that your technology can keep up with customer expectations? Is the

obstacle in your organization IT' ability to get the job done securely?.Participating in IDCFinancial Insights and IBM's breakfast briefing will provide you with invaluable and practical

advice and examples of best practice about how to:

Decide what the real barriers are in your organization

Enable Web self service for any transaction and information set securely

Overcome legacy issues in deploying services that your customers need

Actively manage the associate system complexity and reputation risk of a complex

infrastructure.

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Introduction:

Before creating this website, all users (actors) used to send their information through

telephones, fax, postal mails or they use person to person contacts with each other. It will take

long time to send their orders through this type of communications. And there may be error in

the process. The administration faces the problems to collect all the orders from dealers and to

analyze the required goods for the corresponding product. And also the information replies will

again a delay process. Administration has to send their orders to suppliers for their required

goods. In the dealers point of view sending their orders in a traditional manner is a risk process

and they have to wait for a long time in order to get reply.The system is a web based

Manufacturing System that enables a Manufacturing company to schedule its manufacturing

operations based on the daily update of sales from its dealers. The system is modeled to be used

by a Manufacturing company, whose main activity is manufacturing different products & then

selling the finished goods through a network of Dealers.To start with, the Stocks of all the

Products manufactured by the company and held in the company warehouse are stored in a

Database. The details that are stored include the quantity of each product held with the company

dealers who hold the stocks of finished products for sale.

Once the sales figures of products sold in the past week are entered by the dealers

over the Internet along with the orders for the next delivery, the schedule for the next week

production will be drawn up. A report of the required raw materials or parts will be drawn up

with approved suppliers for each & the suppliers will be intimated about the part requirement

over the internet & asked to quote their rates .The message asking for a quotation will be sent asan e-mail message. Once the rates are quoted, the order will be placed with the required delivery

schedules.

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CHAPTER - 3

RESEARCH METHODOLOGY

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3.1 Research Methodology:He present invention relates to articles of manufacture prepared from a material

web, and in particular to the manufacture of plastic bag rolls suitable for use in most application,

including for example, trash can liners, produce bags, and the like. Plastic bag rolls are typically

built by continuously extruding plastic film through a die to form a bubble. The bubble, tubular

in shape, is later reduced in width to that of the desired bag by flattening the shape and

introducing folds known as gussets using rollers. Once flat, the web may be printed before

conversion into bags. Timing marks may be incorporated into the print. Two types of machines

are usually involved in the final step, known as conversion. The first machine, commonly

referred to as the `bag machine,` perforates and seals the bag web at intervals that determine the

length of the final bag. The seals and perforation are approximately perpendicular to the web.

The second machine, commonly known as the `winder,` separates the web at the perforation if an

overlapped bag is being built but always winds the web into a roll while counting the bags. The

`winder` automatically transfers a new spindle into the web to continue winding bags when a roll

has been completed. Because the perforation is introduced onto the web in a different machine

than the machine that winds the roll, the `winder` must synchronize its operation to the location

of the perforation and seal. The device used to determine the location of the perforation on the

web is referred to as the `counter.` The most prevalent form of counter is a perforation spark gap

detector. This design incorporates two electrodes at a high voltage potential, one on each side of

the web, at close proximity. When the plastic bag is between the electrodes, it acts as an

insulator. However, when the perforation section passes the electrodes, the insulator is

compromised and a spark can jump the gap between the electrodes. Such a design is not alwayssatisfactory, as the high voltage used for sensing also induces a static bond between the layers of

the plastic bag. This effect increases the difficulty that a person will have in opening the bag.

Furthermore, the presence of an exposed high voltage device on the input of the winding

machine often causes operator shocks. Moreover, the sensor can only detect the perforation, and

not any other features of the bag and/or plastic bag web.

Therefore, a need in the art has been identified to provide a sensor system to identify,

track, locate, and/or measure features associated with a plastic bag web, such as bag seals,

perforations, printed markings, skirt length, or other features on the plastic roll, bag or bag web.

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CHAPTER - 4Main Body of the Project

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Many companies that were once centrally involved in the actual manufacture of

products, and the delivery of their supporting services, now find themselves primarily engaged in

integrating a number of other organizations, some of which they may own but many of which

will be independent, each of which goes to make up a particular supply network. Consequently,

continuously tracking performance of suppliers and an appropriate selection mechanism is one of

the crucial activities in managing this supply network.

This paper presents an intelligent generic supplier management tool (GSMT) using the

case-based reasoning (CBR) technique for outsourcing to suppliers and automating the decision-

making process when selecting them. The development of GSMT and how the CBR technique is

applied is then given, followed by an application of GSMT in Honeywell Consumer Products

(Hong Kong) Limited. Emerald Management Xtra presents an entirely new approach to the

provision and use of management information. It was developed by talking through the ideas,

problems and headaches of our academic community members including deans, directors,researchers, teachers, students and librarians in business schools and university management

departments worldwide.

Audience

Librarians

Students

Faculty researchers

Deans

Features

175 full text journals

Reviews from the worlds top 300 management journals Access to over 85,000 full text

management articles of the highest caliber

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Benefits

By bringing together integrated access to journals, reviews and user-centric support resources,

Emerald Management Xtra helps position the library at the heart of a university's service

provision.

It offers much more than journals in a library or papers online; Emerald Management Xtra

provides the opportunity to exchange ideas and information, get to know what is happening in

the world of research work-in-progress, find out what relevant conferences are being planned and

read reviews of previous ones. It enables the sharing of ideas about teaching, from planning a

course, to helping a new student group bond together, to finding an interesting case study. It

provides help and ideas on writing papers for publication, and helping new faculty and graduates

craft their first published piece.

Content

Emerald Management Xtra offers an extending collection of 85,000 full text articles from 175 peer-reviewed journals published by Emerald.

Emerald articles provide you with access to the latest research and global thinking. The sheer

quantity of high-quality papers will enhance your library collection, and covers all major

management disciplines such as marketing, managing people, economics and social policy,

strategy, and financial management.

Management Reviews

Emerald Management Xtra comprises 175 management titles published by Emerald plus a

further 300 of the world's best management and business journals taken from Emerald

Management Reviews (these are selected by an independent accreditation board of industry

experts).

4.1 Concept

This paper provides a demonstration of harnessing the power of the Internet to enable

collaborative manufacturing in such a setup where the key components such as the human

resource personnel and the manufacturing equipment are geographically separated. As part of theframework a platform independent and cost-effective means of remotely operating a 3-axis

computer numerical control (CNC) drilling machine securely via the Internet has been

developed. In addition, an infrastructure to allow remote manufacturers to collaborate on a

product design as well to monitor the drilling process in real time is presented.

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The framework rests on sound security foundation implemented using

technologies such as firewall, authentication modules and transport layer security (TLS) protocol

to promote safe usage of the drilling machine. It is worth mentioning that the architectural design

is generic and modular in nature and as such, any other genre of CNC machine such as milling

and turning could be substituted in place of drilling with only machine-specific changes to the

existing system.

Keywords: Virtual enterprise; Collaborative manufacturing; Web-based distributed

system; CNC machine; Remote control; Security

M1 by B&G is an enterprise resource planning (ERP) software system designed for small to

medium manufacturers including job shops, custom and mixed mode manufacturers and makes

to order manufacturers. M1 by B&G provides total integration and automation from quoting

through invoicing and is capable of flexible and fully supported customization that ensures

youre most valuable & unique business processes can be handled with ease.

Billing System Integration

CRM Integration

Custom User Interface

Customizable Fields

Customizable Functionality

Customizable Reporting

Data Import/Export

Document Management

ERP Integration

Financial Integration

Forecasting

Mobile Access

Multi-Currency

Quality ManagementQuote Management

Reporting

Resource Management

Supplier Management

Supply Chain Management

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4.2 NEED FOR THIS STUDY

A comprehensive review is given of recent research on developing Web-based

manufacturing systems. First, the key issues in developing Web-based manufacturing systems,

including collaboration among product development partners, data modeling, system architecture

design, and security management, and researches to address these key issues are presented. Then

various approaches of developing Web-based manufacturing systems are introduced to show

how these approaches can improve the efficiency and quality in product design, production, life-

cycle integration, enterprise management and customer service. Problems of the currently

developed Web-based manufacturing systems and future work for developing the next-

generation Web-based manufacturing systems are subsequently discussed.

The actual problem is to create a website for the manufacturing company which deals about theManufacturing Companys dealers, products of the company, suppliers for the company,

quotations passing between the dealers and company & suppliers and company administrations

and ordering the products from the dealers to company and so on. The issues provided are

differing for administration of the company, dealers and for the suppliers. The main objective of

this site is:

Maintaining the company administration

Ordering the products from dealers

Fetching the suppliers and Quotations. The actors of this system are company administration,

dealers and suppliers. This system is designed such a way that the actors can easily interact with

the system with minimum knowledge to browser the net and company rules.

Features

Company details

Product details

Order detailsReports

Reports from dealers on order wise

Daily reports from administrator to manufacturer

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4.3 PROBLEM

Many of our materials are anisotropic yet do not wrinkle. Perhaps the best-known

exception is when the material is skewed. Skew means that the principle axis of the material is

not precisely aligned with the MD. Think of the grain of poor quality wood that may be crooked

with respect to the edge of a sawed board. Materials at the edges of cast film lines, all tendered

films and all paper machines exhibit this property to one degree or another. This makes the edges

more wrinkle prone.

However, I believe the reasons for your wrinkling may be more mundane and should be

figured out. Rollers (alignment and diametric variation across the width) and web (bagginess,

possibly at the local level) are the most likely reasons provided that there is absolutely no hygro-

thermal expansion whatsoever.

A roller does not have to be kicking off a continuous wrinkle to be a problem. If

slightly misaligned, a crooked roller may be ok on a perfect web. Conversely a slightly baggy

web can run on a perfect machine. What might not work is a slightly baggy web on a slightlymisaligned machine. In other words, insults add up.

After you have made every reasonable effort to identify and correct the root cause then is

the time to pursue effective spreading. Effective means the right type (not too much, not too

little) and in the right location (where the wrinkle is being initiated; one roller upstream won't

work, one roller downstream is too late)

A starring pattern that differs on the two sides of the same wound roll is often due to a

profile problem in manufacturing; i.e. gage variation. (Other causes are usually easy to

distinguish such as an extremely crooked winding machine that would yield consistent results

and dropping one side of a roll). So let us suppose you have two materials bonded together: film

A and film B. A working theory might be that one of the two web materials or one adhesive layer

is uneven, causing the roll to collapse (star) in a local area where the relative gage is ever-so-

slightly smaller.

One other observation is that the starring is not the classic pattern involving the bottom

of the roll. Rather, it is vividly banded and these bands vary in width and position for every roll

and are different on all sides of all rolls within a set. Further let us constrain the problem evenmore. Let us say that this is a medical grade so that substituting raw material supplier is not

permitted. (Swapping materials is a strong problem solving technique because if the problem

moves with the swap, it is that material). Who is at fault?

Often, less than you can measure on the web. Gauge variation that can cause the web to

be stretched into bagginess might range from less than 1% to occasionally more than 10%.

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Alternatively, we may use the wound roll itself to measure the accumulated variation. The

wound roll is often the most sensitive measure of gauge variations. More importantly, the wound

roll is often the fussiest customer for gauge variation. More about this topic can be found in my

2001 paper Secrets of a Level Process and Product that can be downloaded from my website,

Roisum.com , as well as through the organizations that hosted the talk such as AIMCAL

(members only) and TAPPI .

You may not, however, need to go measuring stuff. If the finished rolls are inconsistent

across the width, then it is very likely that the web is as well. If the winder operator complains

that the web runs like crap, it may be that the web is crap. If the end-use customer is complaining

that the roll looks and runs like crap, it is possible that the root cause is in fact that the web is

crap. More specifically, the web has a profile problem.

Lets do some problem solving. Let us say you have two different substrates that you

bond together to make a structure. The problem is bagginess on the front side first seen after

unwinding the now laminated wound roll. The problem is perennial. This means that while itmay vary in magnitude, sometimes even disappearing from complaint; it stubbornly likes to

misbehave just inside the front edge of the composite web. On close inspection you note that the

diameter of the roll is ever so slightly larger there. The easiest way to see this is with a straight

bar, it rocks over the tiny bump. You may even notice a relatively higher roll hardness reading

via Rhometer, Schmidt Hammer or ParoTester. So whose fault is it?

Many Web-based systems have been developed for solving special design problems.

Ou-Yang and Chang (1999) developed a Web-based integrated intelligent environment to

support design change process for an axial piston pump. The system is composed of two

modules, a constraint network module to analyze the related constraints about a design change to

find the influenced design variables and a product assembly module to extract the design data

from a CAD database to analyse the spatial relationships in an assembly. Cheng et al. (2000,

2001) presented a Web-based intelligent system to support design of rolling bearings. Su and

Amin (2001) introduced a CGI-based approach for remotely executing a large program that is

used for optimal design of gears. Rohl and Kolonay (2001) implemented a Web-based system for

intelligent scaling and detailed finite element analysis of compressor rotors and compressor blades using the Federated Intelligent Product Envi Ronment (FIPER) framework. Yin et al.

(2002) developed a Web-based system for collaborative design of spatial cam mechanisms. Ahn

et al. (2002a) developed a Web-based system to integrate a number of software tools for design

and manufacturing of automobile lighting components.

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This Web-based system was also compared with a CAD-based design and manufacturing

system. It showed that the Web-based tools provided comparable functionality with the CAD-

based tools in terms of performance and usefulness. For the criteria of accessibility, the Web-

based tools out-performed the CAD-based tools. Wang (2002) developed a distributed system for

design and manufacturing of motorcycles using the technologies of Web and CORBA. Xie et al.

(2002) developed a Web-based mould product development information management system for

a cross-nation manufacturing corporation in New Zealand. STEP and CORBA were employed to

implement this information management system.

4.4 OBJECTIVES

Customer self-service is a proven contributor to cost savings in financial services

organizations. Your customers expect secure access around the clock to their entire portfolio

without the need to interact with your employees. However, as a financial services organization,

you will need to ensure that this is done safely and securely, which can often be a challengewhen faced with legacy systems and the pressure of cost reductions.

Although Web-based applications are numerous, the complexity and

interconnectedness of the web and web 2.0 poses significant challenges. Management wants to

increase the breadth of customer interaction while at the same time control the risks and ensure

high levels of security, accessibility, compliance and privacy. Most organizations find achieving

the balance between the needs of the business and the constrains of IT is the real challenge.

So how can you ensure that your technology can keep up with customer expectations? Is the

obstacle in your organization IT' ability to get the job done securely?

Participating in IDC Financial Insights and IBM's breakfast briefing will provide you

with invaluable and practical advice and examples of best practice about how to:

Decide what the real barriers are in your organization

Enable Web self service for any transaction and information set securely

Overcome legacy issues in deploying services that your customers need

Actively manage the associate system complexity and reputation risk of a complex

infrastructure.

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4.5 PROCEDURE METHODOLOGY

He present invention relates to articles of manufacture prepared from a material web, and

in particular to the manufacture of plastic bag rolls suitable for use in most application, including

for example, trash can liners, produce bags, and the like. Plastic bag rolls are typically built by

continuously extruding plastic film through a die to form a bubble. The bubble, tubular in shape,

is later reduced in width to that of the desired bag by flattening the shape and introducing folds

known as gussets using rollers. Once flat, the web may be printed before conversion into bags.

Timing marks may be incorporated into the print. Two types of machines are usually involved in

the final step, known as conversion. The first machine, commonly referred to as the `bag

machine,` perforates and seals the bag web at intervals that determine the length of the final bag.

The seals and perforation are approximately perpendicular to the web. The second machine,

commonly known as the `winder,` separates the web at the perforation if an overlapped bag is

being built but always winds the web into a roll while counting the bags. The `winder`automatically transfers a new spindle into the web to continue winding bags when a roll has been

completed.

Because the perforation is introduced onto the web in a different machine than the

machine that winds the roll, the `winder` must synchronize its operation to the location of the

perforation and seal. The device used to determine the location of the perforation on the web is

referred to as the `counter.` The most prevalent form of counter is a perforation spark gap

detector. This design incorporates two electrodes at a high voltage potential, one on each side of

the web, at close proximity. When the plastic bag is between the electrodes, it acts as an

insulator. However, when the perforation section passes the electrodes, the insulator is

compromised and a spark can jump the gap between the electrodes. Such a design is not always

satisfactory, as the high voltage used for sensing also induces a static bond between the layers of

the plastic bag. This effect increases the difficulty that a person will have in opening the bag.

Furthermore, the presence of an exposed high voltage device on the input of the winding

machine often causes operator shocks. Moreover, the sensor can only detect the perforation, and

not any other features of the bag and/or plastic bag web.

Therefore, a need in the art has been identified to provide a sensor system to identify,

track, locate, and/or measure features associated with a plastic bag web, such as bag seals,

perforations, printed markings, skirt length, or other features on the plastic roll, bag or bag web.

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SUMMARY OF THE INVENTION

These particular objects and advantages may apply to only some embodiments falling

within the claims and thus do not define the scope of the invention. In one aspect of the present

invention a sensing system adapted for use in monitoring and detecting features of a web for

manufacturing is disclosed. The sensing system includes an energy source adapted to project an

energy beam onto the web and a sensor positioned relative to the web and the energy source to

sense attenuation of the energy beam from the energy source to detect, locate or measure the web

or features of the web. In a preferred form, the energy source is a light source and the energy

beam is a light beam. The energy source is positioned on one side of the web and the sensor is

aligned with the energy source on an opposite side of the web so that the web passes between the

energy source and the sensor. In a preferred form, at least a portion of the energy beam is

transmitted through the web so that the portion of the energy beam passing through the web is

sensed by the sensor. The sensing system also includes a comparator in data communication with

the sensor to measure a difference in energy between the energy beam and the portion of the

energy beam that passes through the web. The sensing system identifies the difference as energysignatures for the web and/or a feature of the web, which may include but are not limited to: a) a

perforation of the web; b) a seal of the web; c) a timing mark of the web; d) a skirt length of the

web; or e) any part or dimension of the web ascertainable by measuring attenuation of the energy

beam.

In another aspect of the present invention, a plastic bag manufacturing machine adapted to

detect the existence and/or location of one or more features in the bag is disclosed. The machine

includes a machine frame with one or more components for supporting and handling a plastic

bag web, an energy source on the machine proximate the plastic bag web to project an energy

beam onto the plastic bag web, and a sensor on the machine proximate the plastic bag web and

the energy source to sense attenuation of the energy beam projected onto the plastic bag web

from the energy source.

In a preferred form, the energy source is a light source, the energy beam is a light beam

and the light source is adjustable in intensity or frequency to be tuned to each specific plastic bag

web or to filter out background light. The energy source may be positioned on the machine on

one side of the plastic bag web and the sensor aligned with the energy source on the machine onan opposite side of the plastic bag web to sense at least a portion of the energy beam passing

through the plastic bag web, or the energy source and the sensor may be positioned on the

machine on one side of the plastic bag web so that the sensor is positioned relative the energy

source and the plastic bag web on the machine on the one side to sense at least a portion of the

energy beam reflected off of the plastic bag web.

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A method of the present invention for detecting and measuring one or more features of a bag

web is also disclosed. The method includes the steps of passing the bag web through a light from

a light source, measuring attenuation of the light from the light source with an optical sensor, and

identifying an optical signature as a function of attenuation for characterizing the bag web and/or

its features. In a preferred form, the method includes the steps of: a) acquiring the optical

signature from the optical sensor with a controller for comparing with a record describing what

optical signatures should have been acquired; and, b) associating the line speed of the bag web

with the record of detections for each optical signature for: i) confirming the presence of each

feature of the bag web, ii) measuring one or more of the features of the bag web, and/or iii)

determining false/positive readings from the optical sensor.

A plastic bag manufacturing machine 10 of the kind that is commercially available is

shown by way of example. Those skilled in the art can appreciate that plastic bag manufacturing

machine could be a paper, plastic, metal or any other web type manufacturing machine. The

plastic bag manufacturing machine 10 could be a bag machine, a winder, a counter as discussedin the Background or any other machine for manufacturing plastic bags suitable for adaptation

with the sensing system 20 of the present invention. The present invention should not be

construed as being limited to plastic bag manufacturing machines only. The present invention

contemplates that sensing system 20 could be used to monitor, detect, or measure features in

other bag webs for manufacturing products where detection by attenuation of an energy beam is

plausible, such as for example bag webs of materials suitable for detecting, measuring, locating,

or monitoring features of the bag web by attenuation of an energy beam transmitted or reflected

off the web.

The plastic bag manufacturing machine 10 of the prior art includes a frame 12 for

supporting one or more rollers 14 or other components for handling, supporting and shuttling the

plastic bag web 16 through the machine. The plastic bag web 16 may be unrolled from a plastic

bag roll, such as bag roll 18, or received from another bag manufacturing machine in

communication with or tied to plastic bag manufacturing machine 10. The plastic bag

manufacturing machine 10 may include controls 24 for operating, controlling and monitoring

machine 10. The plastic bag manufacturing machine 10 may also be operated by being linked up by wire or wirelessly with computer 22. Those skilled in the art can appreciate that computer 22

could be any programmable or other controller unit, such as a programmable logic controller

(PLC). The controller may include a data store. Computer 22 could be in data communication

with plastic bag manufacturing machine 10 to monitor operating parameters of machine 10 such

as line speed of the plastic bag web 16.

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Computer 22 may also be in data communication with sensing system 20 for monitoring,

controlling or tuning sensing system 20. The computer 22 or alternatively a controller with a data

store could receive and store information, such as readings from sensor 36 (shown in FIG. 3A-B

and 4). The computer 22 or alternatively a controller could also be used to control operation of

sensing system 20.

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CHAPTER 5

ANALYSIS

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5.1 ANALYSIS OF THE SITUATION

1. SYS_ADMIN

S.NO FIELD_NAME FIELD_TYPE SIZE CONSTRAINT

1 Emp id Varchar2 10 NOTNULL

2 Emp name Varchar2 10 NOTNULL

3 U id Varchar2 10 Primary key

4 Username Varchar2 10 NOTNULL

5 Password Varchar2 6 NOTNULL

6 User type Varchar2 1 NOTNULL

2. MAN_PTYPE_DETAILS

S.NO FIELD NAME FIELD_TYPE SIZE CONSTRAINT

1 P no Varchar2 6 Primary key

2 P name Varchar2 10 NOTNULL

3 Description Varchar2 200

4 Quality Varchar2 1 NOTNULL

5 Exp-time Date NOTNULL

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3. MAN_RAW_PRODUCT

S.NO FIELD_NAME FIELD_TYPE SIZE CONSTRAINT

1 P no Varchar2 6 Foreign key

2 Rp name Varchar2 10

3 Qty Varchar2 3

4. MAN_PCOST_DETAILS

S.NO FIELD_NAME FIELD_TYPE SIZE CONSTRAINT

1 P no Varchar2 6 Foreign key

2 P name Varchar2 10 NOTNULL

3 Rm cost Varchar2 8,2

4 Dp ft Varchar2 3

5 Trt Varchar2 3

6 Cst Varchar2 3

7 Lst Varchar2 3

8 Tcost Varchar2 10,2

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5. MAN_STOCK

S.NO FIELD_NAME FIELD_TYPE SIZE CONSTRAINT

1 P no Varchar2 6 NOTNULL

2 Stock Varchar2 4 NOTNULL

6. MYSTOCK_TAB

S.NO FIELD_NAME FIELD_TYPE SIZE CONSTRAINT

1 P no Varchar2 6 Foreign key

2 Dealer No Varchar2 8 Foreign key

3 Stock Varchar2 6 Foreign key

7. RETURNS_TAB

S.NO FIELD_NAME FIELD_TYPE SIZE CONSTRAINT

1 P no Varchar2 6 NOTNULL

2 Dealer No Varchar2 8 NOTNULL

3 Qty Varchar2 4 NOTNULL

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8. DLR_ORDER_TAB

S.NO FIELD_NAME FIELD_TYPE SIZE CONSTRAINT

1 Order No Number 6 Primary key

2 Dealer No Varchar2 8 Foreign key

3 Delivery date Date NOTNULL

4 Tot cost Number 10,2 NOTNULL

9. DLRORDER_PRODUCTS

S.NO FIELD_NAME FIELD_TYPE SIZE CONSTRAINT

1 Dealer No Varchar2 8 NOTNULL

2 Order No Number 8 Foreign key

3 P no Varchar2 6 Foreign key

4 Qty Number 4 NOTNULL

10. DLRPART_DETAILS

S.NO FIELD_NAME FIELD_TYPE SIZE CONSTRAINT

1 Partnership No Number 8 Primary key

2 No p Number 2 NOTNULL

3 Dealer No Varchar2 8 Foreign key

11. DLRCOMM_DETAILS

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S.NO FIELD_NAME FIELD_TYPE SIZE CONSTRAINT

1 Dealer No Varchar2 8 Primary key

2 Firm name Varchar2 20 NOTNULL

3 Phoner Number 10 NOTNULL

4 Phoneo Number 10 NOTNULL

5 Fax Number 5 NOTNULL

6 Email Varchar2 20 NOTNULL

7 Cstno Number 10 NOTNULL

8 Lsat no Number 10 NOTNULL

9 Cst date Date NOTNULL

10 Last date Date NOTNULL

11 Bname Varchar2 25 NOTNULL

12 Branch Varchar2 20 NOTNULL

13 Acc no Number 10 NOTNULL

14 Dlr type Varchar2 10 NOTNULL

12. DLRCOMP_DETAILS

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S.NO FIELD_NAME FIELD_TYPE SIZE CONSTRAINT

1 Dealer No Varchar2 8 Foreign key

2 C name Varchar2 20

3 CEO Varchar2 10 NOTNULL

4 Estddt Date NOTNULL

13. DLRPART_TAB

S.NO FIELD_NAME FIELD_TYPE SIZE CONSTRAINT

1 Partnership no Varchar2 10 Primary key

2 Name Varchar2 15 NOTNULL

3 DOB Date NOTNULL

4 Address Varchar2 20 NOTNULL

5 Tel no Number 10 NOTNULL

6 Email Varchar2 20

7 Status Varchar2 4 NOTNULL

14. DLR_PROP

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S.NO FIELD_NAME FIELD_TYPE SIZE CONSTRAINT

1 Dealer No Varchar2 8 Foreign key

2 Prop name Varchar2 15

3 Address Varchar2 20

4 Phone Number 10

5 DOB Date NOTNULL

6 Email Varchar2 20

15. ADMIN_ORDER_TAB

S.NO FIELD_NAME FIELD_TYPE SIZE CONSTRAINT

1 P no Varchar2 6 Foreign key

2 P name Varchar2 10 NOTNULL

3 Qty Number 4 NOTNULL

4 Stock Number 4

16. ADMIN_DELIVERY

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S.NO FIELD_NAME FIELD_TYPE SIZE CONSTRAINT

1 Delivery no Number 10 Primary key

2 Order No Number 10 NOTNULL

3 Delivery date Date NOTNULL

4 Dealer No Varchar2 8 NOTNULL

17. ADMIN_LEVELS

S.NO FIELD_NAME FIELD_TYPE SIZE CONSTRAINT

1 P no Varchar2 6 Foreign key

2 P name Varchar2 8 NOT NULL

3 Max Number 4 NOTNULL

4 Min Number 2 NOTNULL

18. DLR_UPDATE_ORDER

S.NO FIELD_NAME FIELD_TYPE SIZE CONSTRAINT

1 Invoice no Number 10 Primary key

2 Doi Date NOTNULL

3 P no Varchar2 6 Foreign key

4 Qty Number 3 NOTNULL

5 Cost Number 10,2 NOTNULL

6 Discount Number 2 NOTNULL

7 Stax Number 2 NOTNULL

19. RAW_STOCK_TAB

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S.NO FIELD_NAME FIELD_TYPE SIZE CONSTRAINT

1 Rp no Varchar2 8 Primary key

2 Rp name Varchar2 8 NOTNULL

3 Rp cost Number 5,1 NOTNULL

4 Rp type Varchar2 1 NOTNULL

5 Qty Number 4 NOTNULL

5.2 EXISTING SYSTEM

Computer-aided manufacturing (CAM) is the use of computer -based software tools that

assist engineers and machinists in manufacturing or prototyping product components. Its primary

purpose is to create a faster production process and components with more precise dimensions

and material consistency, which in some cases, uses only the required amount of raw material

(thus minimizing waste), while simultaneously reducing energy consumption. CAM is a

programming tool that makes it possible to manufacture physical models using computer-aided

design (CAD) programs. CAM creates real life versions of components designed within a

software package. CAM was first used in 1971 for car body design and tooling.

Overview

Traditionally, CAM has been considered as a numerical control (NC) programming

tool wherein three-dimensional (3D) models of components generated in CAD software are used

to generate CNC code to drive numerically controlled machine tools .

Although this remains the most common CAM function, CAM functions have

expanded to integrate CAM more fully with CAD /CAM/ CAE PLM solutions. As with other

Computer-Aided technologies, CAM does not eliminate the need for skilled professionals such

as Manufacturing Engineers and NC Programmers. CAM, in fact, both leverages the value of the

most skilled manufacturing professionals through advanced productivity tools, while building the

skills of new professionals through visualization, simulation and optimization tools.

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Early Use of CAM

The first commercial applications of Cad were in large companies in the automotive and

aerospace industries for example UNISURF in 1971 at Renault for car body design and tooling.

Historical shortcomings

Historically, CAM software was seen to have several shortcomings that necessitated an

overly high level of involvement by skilled CNC machinists. Fallows created the first CAM

software but this had severe shortcomings and was promptly taken back into the developing

stage. CAM software would output code for the least capable machine, as each machine tool

interpreter added on to the standard g-code set for increased flexibility. In some cases, such as

improperly set up CAM software or specific tools, the CNC machine required manual editing

before the program will run properly. None of these issues were so insurmountable that a

thoughtful engineer could not overcome for prototyping or small production runs; G-Code is a

simple language. In high production or high precision shops, a different set of problems wereencountered where an experienced CNC machinist must both hand-code programs and run CAM

software.

Integration of CAD with other components of CAD/CAM/CAE PLM environment

requires an effective CAD data exchange . Usually it had been necessary to force the CAD

operator to export the data in one of the common data formats, such as IGES or STL , that are

supported by a wide variety of software. The output from the CAM software is usually a simple

text file of G-code , sometimes many thousands of commands long, that is then transferred to a

machine tool using a direct numerical control (DNC) program.

CAM packages could not, and still cannot, reason as a machinist can. They could not

optimize tool paths to the extent required of mass production. Users would select the type of tool,

machining process and paths to be used. While an engineer may have a working knowledge of g-

code programming, small optimization and wear issues compound over time. Mass-produced

items that require machining are often initially created through casting or some other non-

machine method. This enables hand-written, short, and highly optimized g-code that could not be

produced in a CAM package.

At least in the United States, there is a shortage of young, skilled machinists entering the

workforce able to perform at the extremes of manufacturing; high precision and mass production.

As CAM software and machines become more complicated, the skills required of a machinist

advance to approach that of a computer programmer and engineer rather than eliminating the

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Typical areas of concern: High Speed Machining, including streamlining of tool paths

Multi-function Machining

5 Axis Machining

Ease of Use

Overcoming historical shortcomings

Over time, the historical shortcomings of CAM are being attenuated, both by providers

of niche solutions and by providers of high-end solutions. This is occurring primarily in three

arenas:

1. Ease of use

2. Manufacturing complexity

3. Integration with PLM and the extended enterprise

Ease in use

For the user who is just getting started as a CAM user, out-of-the-box capabilities

providing Process Wizards, templates, libraries, machine tool kits, automated feature based

machining and job function specific tailor able user interfaces build user confidence and speed

the learning curve. User confidence is further built on 3D visualization through a closer

integration with the 3D CAD environment, including error-avoiding simulations and

optimizations.

Manufacturing complexity

The manufacturing environment is increasingly complex. The need for CAM and

PLM tools by the manufacturing engineer, NC programmer or machinist is similar to the need

for computer assistance by the pilot of modern aircraft systems. The modern machinery cannot

be properly used without this assistance. Today's CAM systems support the full range of

machine tools including: turning, 5 axis machining and wire EDM. Todays CAM user can easily

generate streamlined tool paths, optimized tool axis tilt for higher feed rates and optimized Z axis

depth cuts as well as driving non-cutting operations such as the specification of probing motions.

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Integration with PLM and the extended enterprise

Todays competitive and successful companies have used PLM to integrate

manufacturing with enterprise operations from concept through field support of the finished

product. To ensure ease of use appropriate to user objectives, modern CAM solutions are

scalable from a stand-alone CAM system to a fully integrated multi-CAD 3D solution-set. These

solutions are created to meet the full needs of manufacturing personnel including part planning,

shop documentation, resource management and data management and exchange.

Machining process

Most machining progresses through four stages, each of which is implemented by a

variety of basic and sophisticated strategies, depending on the material and the software

available, the stages are:

RoughingThis process begins with raw stock, known as billet , and cuts it very roughly to shape of

the final model. In milling, the result often gives the appearance of terraces , because the strategy

has taken advantage of the ability to cut the model horizontally. Common strategies are zig-zag

clearing , offset clearing , plunge roughing , rest-roughing .

Semi-finishing

This process begins with a roughed part that unevenly approximates the model and cuts

to within a fixed offset distance from the model. The semi-finishing pass must leave a small

amount of material so the tool can cut accurately while finishing, but not so little that the tool

and material deflect instead of shearing. Common strategies are raster passes , waterline passes ,

constant step-over passes , pencil milling .

Finishing

Finishing involves a slow pass across the material in very fine steps to produce the finished

part. In finishing, the step between one pass and another is minimal. Feed rates are low and

spindle speeds are raised to produce an accurate surface.

Contour millingIn milling applications on hardware with five or more axes, a separate finishing process

called contouring can be performed. Instead of stepping down in fine-grained increments to

approximate a surface, the work piece is rotated to make the cutting surfaces of the tool tangent

to the ideal part features. This produces an excellent surface finish with high dimensional

accuracy.

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Software providers today

The largest CAM software companies (by revenue 2005) are UGS Corp (now owned by

Siemens and called Siemens PLM Software, Inc) and Dassault Systmes , both with over 10% of

the market; CAM Works (From Geometric Ltd) is the first CAM package with Automatic

Feature Recognition Technology, PTC, Hitachi Zosen and Del-cam have over 5% each; while

Planit- Edgecam , Tebis , Top-Solid , CATIA , CNC (Master cam) , Solid CAM , DP Technology 's

ESPRIT , One CNC , and Sescoi between 2.5% and 5% each. The remaining 35% is accounted for

by other niche suppliers like T-FLEX , Dolphin CAD/CAM , Mec Soft Corporation , Surf-CAM ,

Bob-CAD , Metamation , Gibbs-CAM , and SUM3D .

5.3 NEED FOR CHANGE IN THE SYSTEM

Plastic bag rolls or plastic bag webs 16 are typically constructed by continuously

extruding plastic film through a die to form a bubble. The bubble, tubular in shape, is later reduced in width to that of the desired bag by flattening the shape and introducing folds known

as gussets using rollers. Once flat, the plastic bag web 16 may be printed on before conversion

into bags. Timing marks may be incorporated into the print. In the final stages of manufacturing

the bag, a machine, referred to as a \"bag machine,\" perforates and seals the plastic bag web 16

at intervals that determine the length of the final bag. Other machines such as a \"winder\" may

separate the plastic bag web 16 at the perforation if an overlap bag is being built, but ultimately,

the \"winder\" winds the plastic bag web 16 into a roll while counting the bags. The winder may

be adapted to automatically transfer a new spindle into the plastic bag web 16 to continue

winding bags when a roll is complete.

Because the perforation 28 is introduced into the plastic bag web 16 in a different

machine than the machine that winds the roll, the winder is adapted to synchronize the operation

to the location of the perforation 28 and the seal 26 on the plastic bag web 16. The device used to

determine the location of the perforation 28 on the plastic bag web 16 is often referred to

as \"counter.\" In the prior art, these counters commonly consist of a perforation spark gap

detector. Spark gap detection incorporates two electrodes at a high-voltage potential, one on each

side of the bagging, at close proximity. When the plastic bag web 16 is between electrodes, it

acts as an insulator.

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However, when the perforation section passes the electrodes, the insulator is compromised and a

spark can jump the gap between the electrodes, which is tracked and identified to determine the

location of the perforation on the plastic bag web. As discussed in the background, such a design

is not always satisfactory, as high-voltage use for sensing also induces a static bond between the

layers of the plastic bag. This effect increases the difficulty that a person will have in opening the

bag. Furthermore, the presence of an exposed high-voltage device on the input of the winding

machine often results in operator shocks. Further, the sensor can only detect the perforation 28

and not any other feature associated with the plastic bag web 16. Because the prior art has these

and other limitations, the sensing system 20 of the present invention has been provided to

identify, track, locate, and measure features associated with the plastic bag web 16, such as bag

seals 26, perforations 28, printed markings 30, or other features on the plastic bag web 16, which

may be identifiable, measurable, locatable, and/or detectable by measuring attenuation of an

energy beam transmitted through or reflected off of the material used for the bag web, such as

plastic bag web 16.One exemplary embodiment of the optical sensor is shown in FIG. 3A. The sensing

system 20 and methods of the present invention may include one or more energy sources 32,

such as a light source or any other source capable of emitting energy beam 34, and one or more

sensors 36, such as an optical sensor, aligned with energy source 32, energy beam 34 and relative

to the plastic bag web 16 such that one or more optically identifiable features (or features

identifiable by attenuation of an energy signal) in the plastic bag web 16 may be detected,

measured, or appositionally identified. In one exemplary aspect of the present invention, plastic

bag web 16 may be passed between the aligned energy source 32 and sensor 36 as illustrated in

FIG. 3A, whereby an energy beam 34, such as a light beam, from energy source 32 is attenuated

as it passes through the plastic bag web 16. The amount of attenuation may be detected at the

sensor 36, such as an optical sensor/detector in the case where the energy source 32 is emitting

light. Thus, by attenuation of energy beam 34 from energy source 32 passing through the plastic

bag web 16, the sensor 36 is able to identify energy signatures associated with each of the

features of the plastic bag web 16. For example, in the case where the energy source 32 is a light

source, attenuation of light from the light source passing through the plastic bag web 16, iscaptured by an optical detector, which associates an optical signature with each of the features of

the plastic bag web 16, such as the seal 26, perforation 28, printed mark 30, or other optically

identifiable features of the plastic bag web 16. Each of these features and other optically

identifiable features of the plastic bag web 16 are optically identifiable because they each possess

different optical characteristics from each other and the rest of the plastic bag web 16.

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Using the differences in optical characteristics of these features, their respective locations and

measurements may be derived. For example, knowing the line speed of the plastic bag web 16,

sensing system 20 could deduct the measurements of one or more features of the plastic bag web

by comparing the time between detections with the line speed of the plastic bag web 16. This

could be accomplished using a detection algorithm operating as part of the sensing system or

computer 22. In the case where the energy source emits light, the attenuation of light from the

energy source 32, as previously discussed, may be detected or measured using a sensor 36, such

as an optical detector. The optical detector may include a phototransistor, photodiode or like

device suitable for measuring attenuation of light source and/or determining an optical signature

(as a function of attenuation) for each feature associated with the plastic bag web 16.

Another exemplary embodiment of the sensing system 20 and methods are illustrated in

FIG. 3B. In this embodiment, the energy source 32 and sensor 36 are aligned and positioned with

respect to the plastic bag web 16 so as to measure or detect variation or attenuation in the energy

beam 34 reflected off of the plastic bag web 16 and/or features of the plastic bag web 16. For example, in the case where the energy source 32 is a light source and the sensor 36 is an optical

sensor, the two may be aligned and positioned with respect to the plastic bag web 16 so as to

measure or detect variances or attenuation in the light to detect changes in the optical

characteristics of the plastic bag web 1 using reflective light as an optional detection scheme. In

this example, the optical detector/sensor may be positioned relative to the plastic bag web 16 and

the light source so that reflected light from the plastic bag web 16 may be detected and

attenuation of the reflected light measured (compare the reflected light to the emitted light) to

distinguish specific features of the plastic bag web 16 from the rest of the plastic bag web 16.

The present system and methods contemplate other options for identifying the plastic

bag web 16 and features of the plastic bag web 16. In one aspect of the present invention,

features of the plastic bag web 16 may be identified, located, and measured by comparing the

measured energy beam 34 or light to a set point or previously measured light level, such as

emitted energy or light levels, that are correlated to or associated with each of the specific

features of the plastic bag web 16, such as the perforation 28, seal 26, printed mark 30, skirt

length (the distance between perforation 28 and seal 26), or other features of the plastic bag web16 identifiable by attenuation of energy beam 34, such as optically identifiable features.

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In another aspect of the present invention, sensing system 20 may be adapted such that the

electrical response of the optical sensor may be compared to a threshold response known to

represent the overall plastic bag web 16 response to determine if a seal 26, perforation 28,

printed mark 30, or other bag features are positioned at the detection aperture between the

detector and light source. Furthermore, a baseline response for the plastic bag web 16 may be

generated and compared with the response received from each of the features of the plastic bag

web 16 when light from the light source is attenuated by transmission or reflection from the

various features on the plastic bag web 16. The comparison algorithm for comparing emitted and

measured light could be part of sensing system 20 and/or computer 22 (shown in FIG. 1). In

other aspects of the present invention, sensor 36 may have features for internal regulation of the

frequency and intensity of the energy source 32, such as the light source, so that it can be tuned

to a particular plastic bag web 16 or to filter out background light radiation. Computer 22 or a

controller in communication with sensing system 20 may also be used to tune the light source to

each specific plastic bag web 16 and/or the background light by comparing emitted andmeasured light readings. In the case where the energy source 32 is a light source, light emitted

from the light source may also be adjustable in intensity or frequency. 4. The sensing system 20

may also be configured to maintain a historical record of detections versus time, line speed of

plastic bag manufacturing machine 10 or other parameters such that various bag characteristics

or features can be determined, measured, located, or identified. The sensing system 20 may

include a controller and data store for processing and storing detection information or operating

cooperatively with computer 22. The sensing system 20 may also be adapted to use this historical

record to substitute missing detection information at the correct intervals, if necessary.

Energy source 32 may include, but is not limited to, a regulator 38 that is adapted to

convert the available power to a suitable form for the energy source 32 whereby the intensity,

frequency, or other parameters of the energy source 32 may be controlled and tuned specifically

to the plastic bag web 16 by controller 46 in communication with regulator 38. In another aspect,

as also illustrated in FIG. 4 relating to sensor 36, the measured signal from detector 38 may be

amplified with amplifier 42 and ultimately compared or correlated to one or more thresholds

associated with the plastic bag web 16 in comparator 44. The signal may be converted from ananalog signal to a digital signal at any point to optimize processing of data from the detector 40,

whether processed in real-time or post-processed with processing algorithms on computer 22 or a

controller with a data store as part of the sensing system 11.

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The regulator 38, energy source 32, detector 40, amplifier 42, and comparator 44 may be

operated by computer 22, a controller or a CPU having a control board and programmed with

code as shown in the FIG. 5 for operating the detection function of the sensing system 20. Using

computer 22 or a controller with a data store not shown, detection data may be collected from the

detector 40, such as signal levels or otherwise, time-stamped or otherwise, to perform analysis of

the signaled response. Signal thresholds may be determined using the comparator 44.

Comparator 44 may be configured to assess statistical methodologies programmed in the

computer 22 or a controller to determine the average response of the detector 40, to further

identify false/positives detections, and/or supply information to controller 46 for operating the

sensing system 20 and/or operational parameters of the plastic bag manufacturing machine 10.

Signal response levels having a time signature and carrying embedded line speed information

reported by the plastic bag manufacturing machine 10 to computer 22 may be used to measure

dimensional parameters of the plastic bag web 16, such as length of the bag, seal 26, perforation

28, printed marks 30, or other optically detectable, measurable, or identifiable features of the plastic bag web 16. Methods of the invention are also disclosed according to one or more

exemplary embodiments. FIG. 5 illustrates a flow chart method for the featured detection

function of the sensor system 20 of the present invention. In one exemplary aspect of the present

invention, sensing system 20 is configured for detecting and measuring one or more features of

plastic bag web 16 for manufacturing plastic bags. Those skilled in the art can appreciate that the

sensing system 20 of the present invention could be used to measure, detect, identify and/or

monitor features associated with any web used in manufacturing, such as a plastic, paper or

metal web. The method includes one or more of the steps of passing the plastic bag web 16

through an energy beam 34, such as light, from an energy source 32, such as a light source, for

measuring attenuation of energy beam 34 from the energy source 32 with a sensor 36. The

method also includes identifying an energy signature, such as an optical signature, as a function

of the resulting attenuation for characterizing the plastic bag web 16 and/or any of its features.

As previously indicated, the methods of the present invention are not limited to

monitoring, identifying, and/or detecting features associated with the plastic bag web 16, but the

methods of the present invention could be used to monitor, detect and/or measure featuresassociated with any web of material, whether plastic, metal or paper webs used in a

manufacturing process that use a web of material. For example, the figures such as FIG. 5

illustrate one exemplary method of the detection function of the present invention or the function

for detecting, monitoring and/or measuring features associated with the web 16 used in

manufacturing.

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The detection function could be started by a user inputting operating parameters such as selecting

the type of material of the web 16 or the type of product to make from the web 16, such as a

plastic bag. Based on these selections, operational parameters of the sensing system 20 are

formulated and can be executed by computer 22 or any type of controller, such as a micro-

controller in communication with an I/O device that in-turn is in communication with other

external hardware structures such as energy source 32, energy beam 34, sensor 36, regulator 38,

detector 40, amplifier 42, comparator 44, and/or controller 46 (as shown in FIG. 4).

Upon operation startup, sensing system 20 may acquire an initial timestamp, which

could be used as a reference point in the detecting process, such as for example providing

information based on the position of the web 16 and/or features in web 16, relative to the

reference point. A second timestamp is taken upon the start of perforation 28 in plastic bag web

16. In the case where the start of a perforation 28 is not detected during the expected interval,

thereby causing the perforation interval to expire, sensing system 20 checks to see if sensor 36

changed state, and if not provides a no detection warning. If the time interval for detecting perforation 28 has not expired, sensing system 20 checks to see if the sensor 36 has changed

state. If sensor 36 has not changed state, sensing system 20 cycles again until a second timestamp

is acquired upon the detection of the start of perforation 28. However, if sensor 36 changes state

(i.e., an energy signal is detected in excess of the standard response for web 16) then sensing

system 20 acquires a third timestamp indicating the end of perforation 28 in plastic bag web 16.

In the case where the bounce interval doesnt expire (i.e., interval of time that the signal response

is what the expected response should be for the feature in question) the system checks to see if

sensor 36 has changed state, and if not repeats the process until either the bounce interval expires

or sensor 36 changes state (indicating a detection of the end of perforation 28). In the case where

the bounce interval has not expired, but sensor 36 has changed state (i.e., a third timestamp has

been acquired for the end of perforation 28), sensing system 20 automatically increments the

perforation bounce counter.

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Alternatively, in the case where the bounce interval has expired (i.e., sensor 36 changed state and

bounce counter was incremented), sensing system 20 acquires a fourth timestamp of the starting

point for seal 26 in plastic bag web 16. In the case where the seal 26 interval (time allotted for

detection of the seal) expires, meaning that no seal 26 was detected and sensor 36 did not change

state, sensing system 20 attempts to reacquire the start of seal 26. If the start of seal 26 is

detected, sensor 36 changes state and a fifth timestamp is acquired at the end of seal 26. In the

case where the interval for detecting seal 26 expires, without a acquiring a fourth timestamp for

the start of the seal 26, sensing system 20 increments the counter for the no seal counter. If the

detection interval for seal 26 has not expired and sensor 36 has changed state, the sensing system

20 continues to cycle until the start of seal 26 is detected.

Sensing system 20 attempts to acquire a fifth timestamp at the end of seal 26. In the case

where the bounce interval doesn't expire (i.e., interval of time that the signal response is what the

expected response should be for the feature in question) and sensor 36 has not changed state,sensing system continues to cycle until sensor 36 changes state indicating a detection of the end

of seal 26. In the case where the bounce interval has not expired and sensor 36 has changed state,

sensing system 20 automatically acquires the fifth timestamp for the end of seal 26 and

increments the seal bounce counter.

Alternatively, in the case where the bounce interval expired (i.e., sensor 36 changed state

and bounce counter was incremented), sensing system 20 applies timing delays and provides an

output pulse which increments the bag counter, which could be alternatively reset externally. In

the case where the seal was detected, the system 20 uses the information to determine and

perform statistical analysis, whether by real time or post processing, to determine dimensions,

locations, and/or detection of the skirt length, seal length or seal bounces for plastic bag web 16.

Alternatively, and in addition to the previous step, in the case where seal 26 was not detected,

sensing system 20 can be used to determine other features associated with plastic bag web 16

such as perforation length, perforation bounces, perforation ratio, and/or bag length.

The embodiments of the present invention have been set forth in the drawings and specification

and although specific terms are employed, these are used in the generically descriptive senseonly and are not used for the purposes of limitation. Changes in the form and proportion of parts

as well as in substitution of equivalents are contemplated as circumstances may suggest or are

rendered expedient without departing from the spirit and scope of the invention as further

defined in the following claims.

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5.4 PROPOSED SYSTEM

The invention concerns a method for the manufacture of a sandwich web in which each

side of a substrate web is coated by means of an adhesive applicator and thereafter combined

with the liner web and bonded, as well as a device to implement the process. DE-AS No. 12 72

410 discloses a sandwich web manufacturing process in which an aluminum foil is led through a

tank containing a solvent and then over a guide roller to a laminating station where a plastic foil

softened by the solvent is pressed onto one side of the said foil.

In this method, it is not possible to coat a substrate web with an adhesive since a device essential

for metering the applied coating is not provided.U.S. Pat, No. 4,055,453 discloses a further

sandwich web manufacturing method for the production of roofing felt in which the inner

surfaces of the outer layers of a three-ply laminate are coated with adhesive and are brought

together and bonded by one and the same roller.

It is not possible with either of the above-described methods to completely affect the rolling

behavior of the finished sandwich web since it is generally known that a web of material coated

with adhesive cannot be withdrawn in an exactly tangential manner from any roller that comesinto contact with the adhesive film. Depending on its own properties and on those of the

adhesive, the web of material will be deflected from the tangential path to a greater or lesser

extent in the direction of its circumferential motion. For this reason it is not possible to perfectly

control the tensions of the individual webs of material.

The present invention provides a method with which it is possible to combine the individual

webs under perfect tension control into a sandwich web in a single operation.

According to the present invention the substrate web is coated with a film of adhesive on both

sides in a first roller nip formed between two applicator rollers which are each advance able

against the other. The substrate web is thereafter led together with a first liner web through the

nip formed by one of the applicator rollers and a first laminating roller and with a second liner

web through a third roller nip formed by the first laminating roller and a second laminating roller

and bonded. The directions of each of the webs which approach the device and which form part

of the sandwich web are arranged before entry into the roller nip by the corresponding roller. The

webs are continuously supported by roller surfaces until the third roller nip has been passed.

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The method according to the present invention makes it possible for every web of the sandwich

web to pass through the apparatus continuously over roller surfaces; to transfer an accurately and

separately metered film of adhesive to both sides of a substrate web within the confines of the

same roller nip; to determine a fixed departure line for the adhesive-coated substrate web; to

influence the tension of each individual web up to the location at which they are laminated; and

to regulate the pressing forces developed in the roller nips between the rollers according to

requirements.

Accordingly it is an object of the invention to provide an improved apparatus for

manufacturing a sandwich web in which a substrate is passed between a first roller nip made up

of adjustably spaced apart readable applicator rollers which apply a uniform film of adhesive to

each side of the substrate and wherein the substrate is then moved into a nip formed between a

first laminating roller and one of the applicator rollers to apply a first laminating web to one side

of the substrate over the adhesive and then is moved to a nip formed between a second

laminating roller and the first laminating roller wherein a second liner is fed over the adhesive onthe opposite face of the substrate.

In the present invention, in a process in which a fiber suspension supplied in a flat layer

manner is subjected to natural dehydration, pressure dehydration, or suction dehydration, while

circulating a cylindrical suction cylinder, and thereby, dehydration slowly proceeds and a paper

web is formed, and this paper web is moved to an endless felt by means of a suction couch roll to

produce paper, a tapered suction roll sleeve 6, the outer peripheral surface of which is cylindrical

and the inner peripheral surface of which has an inclination identical to that of the outer

circumference of the tapered suction roll cell 5 is attached and detached, and thereby, it becomes

easy to conduct the attachment and detachment of various types of wires wound on tapered

suction roll sleeve 6.

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A web-based rapid prototyping and manufacturing (RP&M) system offers a collaborative

production environment among users and RP&M providers to implement the remote service and

manufacturing for rapid prototyping, to enhance the availability of RP&M facilities, and to

improve the capability of rapid product development for various small and medium sized

enterprises. This chapter first provides a comprehensive review of recent research on developing

web-based rapid prototyping and manufacturing systems. In order to meet the increasing

requirements of rapid product development, an integrated manufacturing system based on

RP&M is proposed. The workflow and overall architecture of a web-based RP&M system are

described in detail. Furthermore, the key technologies for developing the Web based RP&M

system, which involve deploying the running platform, determining the system model, choosing

a server-side language, constructing development platform as well as designing the database and

developing application, are also discussed. Finally, a case study is given to demonstrate the

application of the web-based RP&M system.

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CHAPTER 6

Present conditions with special reference to the organization

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6.1 DESIGN PRINCIPLES & EXPLANATION

MODULES

The main modules of this Web based Manufacturing System are broadly divided into

three. They are

Administration module

Dealer maintenance module

Supplier maintenance module

MODULE DESCRIPTION

Administration module:

It is the main module of the system handle by administrator and staff members of the system. In

this module the key actor is administrator he was the superior of the entire system.

Dealer maintenance module:

This is also one of the key modules of the system, the order of the required products take place

by the dealer. In this module key actor is dealer.

Supplier maintenance module:

This is also one of the key modules of the system, the required number of parts to the

administration done by the supplier .In this module the key actor is supplier.

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PROJECT DICTIONARY

DATAFLOW DIAGRAMS

First level DFD:

SECOND LEVEL DFD:

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Administrator Dealer

Web BasedManufacturingSystem

Sys Administrator

Warehouse Stockiest Raw Stockiest

Manufacturer Manufacturer

System administrator

Raw StockiestAdministrator

Manufacturer Dealers

WBMS

Re uest Products

Producefinished Goods

Receive rawMaterial

Receives Products

Sys Admin

Changes userid &assword

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Raw Stockiest:

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LoginManaging Users

Enters into the site

Usernames table Usernames table

Create userid& password

Informationabout users

Raw Stockiest

Maintains CostDetails

Receives Orders

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Manufacturer DFD:

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Raw Stock Table Raw Product Table

Manufacturer

Order For Raw Material

Store theFinishedGoods

Product CostDetails

Product TypeDetails

Product Details Table Product Cost DetailsTables

Manufacturer Stock Table

Raw Product Tables

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Administrator DFD:

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Administrator

VerifyProducts

Order for products

QuotationStatus

Dealers orders Table

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ER diagram

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Dealer

Partnership

PType

No

cstno

Phoneno

Type

DealerNoFax

Email

FirmNam

e Bank name branch

A/C NoMax.stock

Company