Methods and systems involving manufacturing sheet products by testing perforations

1. A method comprising:

receiving a first image of a first line of perforations in a sheet product;

processing the first image to determine whether the first line of perforations are within specifications, wherein the specifications include at least one of a width of one or more perforations, a length of one or more perforations and a spacing of one or more perforations in the first line of perforations;

outputting an indication to an operator indicative that the first line of perforations are not within specifications responsive to determining that the first line of perforations are not within specifications;

adjusting a perforating arrangement by:

changing, in response to the determination, an amount of a distance between an anvil roller and a perforations roller, wherein the sheet product is disposed between an overlapping portion of the anvil roller and the perforations roller which are disposed on opposing sides of the sheet product; and

advancing the sheet product such that a subsequently formed line of perforations in the sheet product is within specifications responsive to determining that the first line of perforations is not within specifications; and

forming the sheet product into a roll.

2. The method of claim 1 , wherein the processing the first image includes comparing the first image with a base image to determine whether the first line of perforations are within specifications.

3. The method of claim 1 , wherein the first line of perforations are formed by the perforating arrangement.

4. The method of claim 1 , wherein the method further comprises:

receiving an image of the roll;

measuring a diameter of the roll;

determining whether the diameter of the roll is within a diameter specification; and

outputting an indication that the diameter of the roll is not within the diameter specification responsive to determining that the diameter of the roll is not within the diameter specification.

5. The method of claim 1 , wherein the method further comprises: incrementing a counter responsive to determining that the first line of perforations is not within specifications.

6. The method of claim 5 , wherein the method further comprises:

determining whether the counter has reached a threshold value responsive to incrementing the counter; and

outputting an indication that the counter has reached the threshold value responsive to determining that the counter has reached the threshold value.

7. The method of claim 1 , wherein the method further comprises setting the counter to zero responsive to determining that the first line of perforations is within specifications.

8. The method of claim 1 , wherein the comparing the first image with the base image comprises comparing a size and shape of the first line of perforations of the first image with a size and shape of the line of perforations of the base image.

9. The method of claim 1 , wherein the method further comprises:

receiving a video image; and

processing the video image to define the first image, wherein the first image includes a frame of the video image.

10. A system comprises:

a first camera; and

a processor operative to:

receive a first image of a first line of perforations formed by a perforating arrangement in a sheet product from the first camera;

process first image to determine whether the first line of perforations are within specifications;

output an indication to an operator indicative that the first line of perforations are not within specifications responsive to determining that the first line of perforations are not within specifications, wherein the specifications include at least one of a width of one or more perforations, a length of one or more perforations and a spacing of perforations in the first line of perforations; and

adjust a perforating arrangement by:

changing, in response to the determination, an amount of a distance between an anvil roller and a perforations roller, wherein the sheet product is disposed between an overlapping portion of the anvil roller and the perforations roller which are disposed on opposing sides of the sheet product; and

advancing the sheet product such that a subsequently formed line of perforations in the sheet product is within specifications responsive to determining that the first line of perforations is not within specifications; and

forming the sheet product into a roll.

11. The system of claim 10 , wherein the processing the first image includes comparing the first image with a base image to determine whether the first line of perforations are within specifications.

12. The system of claim 10 , wherein the system further comprises a visual indicator communicatively connected to the processor.

13. The system of claim 10 , wherein the system further comprises:

a roll forming apparatus; and

a second camera.

14. The system of claim 13 , wherein the processor is further operative to receive an image of the roll from the second camera, measure a diameter of the roll, determine whether the diameter of the roll is within a diameter specification, and output an indication that the diameter of the roll is not within the diameter specification responsive to determining that the diameter of the roll is not within the diameter specification.

15. The system of claim 10 , wherein the processor is further operative to increment a counter responsive to determining that the first line of perforations is not within specifications.

16. The system of claim 10 , wherein the processor is further operative to set the counter to zero responsive to determining that the first line of perforations is within specifications.

17. The system of claim 16 , wherein the processor is further operative to determine whether the counter has reached a threshold value responsive to incrementing the counter, and output an indication that the counter has reached the threshold responsive to determining that the counter has reached the threshold.

18. The system of claim 10 , wherein the comparing the first image with the base image comprises comparing a size and shape of the first line of perforations of the first image with a size and shape of the line of perforations of the base image.

19. The system of claim 10 , wherein the system further includes a backlight arrangement operative to illuminate the first line of perforations.