CH691940A5 - Control and monitoring interface unit for automatic machine for wrapping products with thermoplastic films - Google Patents

Abstract

The unit (1) for effecting measurements, tests, maintenance operations and looking up data and statistics on an automatic machine, is housed in a small rectangular case, and is the interface between the automatic industrial machine (12), a personal computer (13), a printer (15) and a number of sensors (17,19,20,22) which monitor the functions of the machine. The interface unit contains a microprocessor (7), timing circuit (9), EPROM and RAM memory circuits (8) and interface circuits (11,14,16,18,21). - The unit control panel has a small LCD display screen (2) and a keyboard (3 to 6, 104). The type of sensors which can be connected includes a digital signal generator (17), an LVDT analogue sensor (19), a magnetic sensor (20) and a bar-code reader (22). The user presses function keys (6), cursor compass keys (5) and a numerical keypad (3,4,104) to control the operation of the unit.

Description

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Description

The invention relates to an apparatus for carrying out, even with remote connections, measurements, tests, inspections, maintenance and data and statistics collection on automatic machines and / or components of such machines. The apparatus in question was in particular designed for the connection of plastic film products to packaging machines where, in addition to the problems inherent in the detection of physical measurements, tolerances, profiles and timing on components and mechanical movements, there are added inherent problems the most difficult to control parameters related to the plastic films used in the packaging of the products and to the infinite dimensional and qualitative variety of the products to be packaged.

The characteristics of the apparatus in question, and the advantages that derive from it, will appear evident from the following description of a preferred embodiment thereof, illustrated purely by way of non-limiting example, in the figures of the seven enclosed drawings, in where:

fig. 1 is a front elevational view of the apparatus, with the various buttons and the display;

fig. 2 is a block diagram which highlights the composition of the apparatus and a possible connection of the same to external parts;

fig. 3 shows a block diagram of the formation of work programs both in the apparatus according to the invention and in the packaging machine of which the apparatus itself will have to check the functionality;

fig. 4 illustrates the block diagram of the phase of storing data in the apparatus, coming from one or more packaging machines to which it can be connected in succession of time or coming from components of the machines themselves, and also illustrates the subsequent transfer of the acquired data to a registration, calculation and processing center;

the fig. 5 and 6 illustrated with a block diagram two possible flow menus of the apparatus in connection with a machine to be controlled;

fig. 7 shows a flow chart of the apparatus during a maintenance intervention on a packaging machine;

fig. 8 illustrates the possible use of the apparatus according to the invention for the remote control of the functionality of a packaging machine to which the apparatus itself is permanently connected.

From fig. 1 it is noted that the apparatus 1 according to the invention comprises a small, parallelepiped-shaped container 101, on whose wall are mounted: a display 2; a group 3 of numeric keys (from 1 to 0); an "Enter" key 4 useful as a confirmation key and a "Clear" key 104 useful as a cancel key; a group of keys 5 with a "scroll" function; a group of function keys 6. When viewing the tips in the "help" table, both keys 3 and 4 can be used, for example, to exit this table. The group of the four keys 5 with the arrows are used: The «Up» and «Down» arrows are normally used to move between the items of the various menus or can be used to increase-decrease the value in a variable field; the "Left" and "Right" arrows are used for moving one page at a time between the various descriptions or menu items, while if variable fields are being edited, they are used for moving between the various items in progress of modification.

On the rear face of the container 101 and / or on its side walls, sockets (not shown) are provided for the operative connection of the apparatus in question to the parts referred to below.

The components indicated in the block diagram of fig. 2 and precisely:

- a microprocessor 7 to which the following units are connected;

- an EPROM and RAM memory unit 8 with an electric buffer battery;

- a unit 9 for managing a calendar 9 suitable for automatically storing dates and times of intervention on the packaging machine;

- the connections to the display 2 already considered;

- the connections to the keyboard 4-104-5-6 which is also already considered;

- a unit 10 for managing digital outputs;

- a unit 11 for the management of serial RS232 and RS485 or others of a suitable type, with relative communication protocols that allow connection to other intelligent systems, such as for example the control computer of the automatic machine to be controlled 12, or a Personal Computer (PC) 13. The apparatus in question receives from the connection with the machine 12 the voltage necessary for operation, while in the case of connection to the PC only, the apparatus itself will be powered through a dedicated socket.

- a RS232 serial management unit 14 for connection to a printer 15;

- a unit 16 for managing digital input signals from a digital sensor 17;

- a unit 18 for managing analog signals from related sensors, for example from an LVDT (Linear Variable Differential Transformer) sensor 19 and from a magnetic sensor 20;

- a unit 21 for managing an optoelectronic pen 22 for reading bar codes.

In addition to the operating system that manages all the various functions of the apparatus itself, in the memory unit 8 of the apparatus, there are already special programs for test, testing and maintenance procedures. There is also the possibility, as indicated below, of inserting programs 8 into the memory unit cut out according to the specific needs of the automatic machine manufacturer. As illustrated in fig. 3, the apparatus is connected via the unit 11 of fig. 2, and through a prom programmer 23 and a program archive 24, to a PC 13 which is also connected via an interface 25 and a prom programmer 26 to the processor 1112 of the packaging machine 12.

From fig. 3 it is further noted that the PC 13 is connected: to a macro system library 27; to a complex 28 compiler and link metaprogram; to a

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complex 29 for basic programs, procedures and routines; to a complex 30 for customizing the programs of the manufacturer of the packaging machines; to a complex 31 for the management of messages and wordings in the various languages.

In order to create programs according to specific needs, the functions present in the library 27 will be used which will simplify the writing of the programs themselves. At the same time, all the messages that will be used by the various programs and that can be managed in the different languages will be typed. After the setting phase, once a program has been executed, the object program is generated through unit 24 which will be transferred to unit Eprom through unit 23.

The manufacturer of the packaging machine, in implementing the computer program that controls the operation of the machine itself, will be able to use its own system to generate the protocol software and interface management, or it will be able to exploit tools similar to those considered in fig. 3 to generate the communication protocol necessary for the transfer of data and information between the computer of the machine and that of the apparatus 1 in question. The programs generated in this way are easy to transport as they are written in "C" language.

The functions present in the system libraries 27, through which the programmer can generate specific programs, can be summarized as follows:

- digital input test;

- digital test outputs;

- analog input test;

- test of intervention times;

- test of analog and / or digital quantities related to a time scale;

- test of movements with feedback;

- special tests, for example measuring the memory of the packaging film or films, measuring the dimensions of the products to be packed and others;

- hardware testing of the packaging machine;

- automatic, semi-automatic and / or manual tests of physical quantities;

- complete check of the individual devices that make up the machine or of the entire packaging machine;

- customizable prints of various types;

- display various information of the packaging machine;

- display and modification of the machine variables;

- continuous display of the byte, input and output values selectable directly by the operator;

- possibility to modify at will any value contained in ram or the various outputs;

- continuous display of sizes that can be selected by the customer such as: size of the tray containing the product to be packaged; length of the stretch of film used in relation to the size of the product; stretches and stresses to which said film is subjected; room temperature; temperature of the heat-sealing plate of the overlapping edges of the packaging film, since all these quantities are expressed in the desired unit of measurement;

- manual and / or automatic updating of the values of the packaging machine;

- activation of procedures;

- possibility to detect and display the phase diagram of the machine;

- perform "trace" functions that allow you to store a sequence of information chosen by the operator, when particular events occur or sequence of events that can be set as desired;

- possibility of introducing into the machine, with random functions, data that can simulate malfunctions, in order to perform a test on the machine software;

- data acquisition, statistics, and other parameters.

The apparatus in question, with external connections as in figs. 2 and 3, will be used in the design and construction phase of the packaging machine, making use of "trace" functions or the detection of phase diagrams in real time or other useful functions for program development.

During the assembly phase of the various components of the machine, the apparatus will allow a guided verification of the assembly itself, phase after phase. The sensors 17-19-20 will allow to realize the necessary physical connection of the apparatus with the various components of the machine and the optoelectronic pen 22 will allow to store the reactive data to the same assembled components. Through PC 13 it will be possible to introduce all the necessary alphanumeric messages in the machine and in the processor of the machine.

During the testing phase of the packaging machine produced, the apparatus will allow to store useful data, as well as to carry out comparative checks and subsequent processing. Through the printer 15 it will be possible to print a folder with the various characteristics of the machine produced.

Finally, the apparatus can be used for the maintenance of the packaging machine to which it will be connected as shown in fig. 2 and in this case it will create a simple consultation tool which, based on the data provided by the machine, advises the maintenance technician on the operations to be performed to eliminate the malfunction and will then allow to perform a complete check of the machine, which can be memorized with a series of other information and data that can then be downloaded to a database (see below).

Fig. 4 illustrates how the same apparatus 1 can be connected to various packaging machines 12-112-212-312, also in different situations, for example one during assembly, the other during testing, the other still during testing final and last undergoing maintenance. Using the optoelectronic pen 22 which is part of the group of sensors connected to the apparatus 1, the block 32 of the data relating to the commercial components existing in the warehouse can be recorded in the memory of this apparatus in relation to the machines for which the same apparatus was designed and the data relating to the components mounted in the machines. Through the display 2 and the printer 15, the necessary data can be viewed on site, in formats customized to the machine and to the specific operation. In a subsequent time, the same apparatus 1 can be connected to a PC 13 with relative monitor

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113 and printer 213, to transfer the acquired data to the mass memories of the computer, for example to a technical database 33, to a statistical database 34 and to an administrative and / or dedicated database 35 for ! parts supply and assistance warehouse.

The device uses windowed menus, some of which can be activated and deactivated through passwords connected to the computer of the machine (see below), to discriminate people who can access the different functions.

Examples of flow menus are shown in figs. 5 and 6. In fig. 5, step 36 indicates the set of data coming from the automatic machine in work.

Phase 37 indicates the display of the packages produced by the machine in one day; step 38 indicates the "help" situations for the machine, "ok" or "warning"; step 39 indicates the information on the last package made. In fig. 6, phase 40 indicates "stop-press start or emergency menu"; phases 37 and 39 are the same as in the flow of fig. 5; phase 41 indicates "help on the emergency occurred"; step 42 indicates "test execution of the packaging machine manufacturer"; phase 43 indicates "consultation of the last 10 errors". If a technical password 44 has been entered in the connection with the machine, the flow of fig. 6 continues with a phase 45 indicating "complete test execution menu", then with phase 46 indicating "menu of various functions"; then with step 47 indicating "menu of machine variables"; then with phase 48 indicating "statistical error consultations"; then with phase 43 which indicates «consultation of the last 10 errors»; then with step 49 indicating "intervention storage menu"; then with phase 50 indicating "password entry menu" and finally with phase 51 indicating "statistical data printing menu". If, on the other hand, a super-technical password 52 is entered in the connection with the machine, it is intended for personnel who are more specialized than those who can work with the previous password 44, at the flow of phases 45-46-47-48—43-49 -50 and 51 already said, step 53 of "PC function menu" is added.

The operator will be guided in the sequence of operations to be performed by the help deriving from the various sensors and devices 17-19-20-22 connected to device 1 and from the various help functions that will be shown on the display of the same device. Each operating phase will be shown on the display 2 and can therefore be checked and the work can be printed via the printer 15 and stored both in the apparatus 1, for subsequent reworking, and in the machine 12 to update the history of its state. As said for the example of fig. 4, the apparatus 1 may contain the programs and information of different types of machines and, within the same machine, of the different versions of this. By storing the identification code, series, machine number and software release in the eprom (or ram with battery or eeprom), the program of the device 1 will automatically choose the appropriate programs, avoiding any possibility of error by the operator.

In fig. 7 shows the sequence of the various operating phases of a possible maintenance intervention following a malfunction of the packaging machine. When the apparatus 1 is connected to the machine, as in the example of fig. 2, after the start phase 54 the connection 55 above is enabled and the display 2 of the same device displays the basic information 56 which can be consulted with a scroll function (keys 5 of fig. 1) if these transfer the dimensions a page. The error code 57 which caused the machine to stop is then displayed, with details of the information relating to this stop. On request, the last ten emergencies 58 which have occurred in chronological order and the statistics 59 of errors and / or warnings are displayed which, although they have not blocked the operation of the machine, have nevertheless been detected by it. Also on request, as indicated with 60, the type of intervention previously carried out, the date of implementation and the operator who performed it can be displayed. At this point, we move on to phase 61 which poses the following question; are the data acquired sufficient to intervene? If not or at its discretion, the operator carries out step 62 which provides for a complete check of the machine in order to identify the error or errors that led to its stopping or malfunction. After this phase or if the data acquired in phases 54 to 60 are sufficient, upon command of the operator the apparatus displays the sequence 63 of the possible causes that caused the inconvenience and then displays the solution (s) 64 to be adopted to solve the inconvenience. If there are more than one solutions, they are indicated with statistically more probable succession. At this point, as indicated by 65, the operator performs the tests suggested by the apparatus 1 and then, having ascertained the solution of the drawbacks or problems, as indicated by 66, the operator himself carries out the repair, preparing the sensors 17 on the machine. -19-20 for the detection of the necessary data, as carried out in the assembly and testing phase of the machine itself. The parts 67 replaced in the machine, by means of the optoelectronic pen and / or other means, are unloaded in the memory of this computer and in that of the apparatus 1, as indicated by 68.

The machine repair step 69 is then reached and the subsequent step 70 consists in carrying out the complete check of the machine to carry out the final checks 71 and 72, automatically and on command of the operator, aimed at verifying that all the machine parameters are within the pre-established tolerances. At this point, the apparatus 1 autonomously records the various statistics 73, the check data 74, the various machine information 75, the intervention data 76 and also commands the recording of the intervention information 77 in the memory. The computer of the machine which will update the various data 78. The intervention cycle ends with a phase 79 of printing the data relating to the machine and the intervention carried out and with the actual end 80 of the intervention.

The information saved in the internal memory

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of the apparatus 1, as already mentioned with reference to fig. 4, will then be downloaded to a central system including PC and different paths will follow depending on whether they are technical information useful for subsequent processing or modification of construction parameters, or administrative data that will be used for billing and for the necessary formalities at the warehouse for replenishing the machine parts. In this same phase, in the apparatus 1 the registration memory will be reset which will thus be available for new interventions.

In addition to the functions described, the apparatus 1 can perform a sophisticated function of signal analyzer for serial communications both RS232 and RS485 with baud rate parity check and number of stop bits programmable as desired by the automatic machine manufacturer. This function is of crucial importance as it increases the need to interface the various packaging machines with other systems. In this case, the apparatus 1 not only interacts directly with the machine, but also detects all the data that the machine and the interfaced system transmit, being able to view, store and subsequently process and print the transmitted data.

Another function that the apparatus 1 can perform and which in the future will become increasingly indispensable, is that illustrated in fig. 8 to allow a remote connection via telephone connection 81 and modem 82-182, between one or more machines 12-112-212 installed at a customer and a PC 13 installed at a maintenance center. From the physical point of view, the apparatus 1 performs in this case a concentrator function, talking with the various machines to which it is connected and simultaneously interfacing with the operator who can therefore intervene remotely. The operator of the maintenance center can thus monitor all the connected machines and achieve the following purposes:

- follow the functionality of one or more machines connected to device 1 during normal operation;

- check if the machine works correctly and check whether preventive maintenance is planned;

- verify the actual need for a maintenance intervention for a fault, with the possibility of distinguishing between;

* an intervention that can be carried out directly by the operator of the user of the machine, on the suggestion of the operator of the maintenance center;

* transfer to the computer of the machine of alternative programs that allow it to work until the next specialized maintenance;

- acquire the maximum number of information before the operator of the maintenance center carries out an intervention for which his presence is required;

- update the computer program of the machine or transfer to these new work programs.

Claims (2)

claims 1. Apparatus for carrying out measurements, tests, inspections, maintenance and data and statistics collection on automatic machines, in particular machines for packaging products with stretch and thermoplastic films, characterized by comprising in a small portable container (101); - a microprocessor (7); - a unit (11) for the management of serial lines, for example of the RS232 and RS485 type with relative sockets for connecting the microprocessor (7) to that of the packaging machine (12) to be controlled and / or to a PC (13); - a memory unit (8), consisting for example of an Eprom or a Ram with buffer accumulator; - a calendar management unit (9), to store the dates and times of intervention on the packaging machine; - a digital output management unit (10); - a unit (14) for managing a printer, with relative socket for connection to the printer itself (15); - a digital input management unit (16) with relative socket for connection to a digital sensor (17); - a unit (18) for managing analog inputs, with relative socket or sockets for connection to one or more analog sensors, for example of the LVDT type (19), of the magnetic type (20) or others; - a unit (21) for managing the data from an optoelectronic pen (22) to which the same unit can be connected via socket; - a liquid crystal display (2) for viewing the processed data; - a keyboard equipped for example with a group of numeric keys (3), a «clear» key (104), an «enter» key (4), a group of «scroll» keys (5) , of a group of function keys (6); all this being provided to ensure that in the apparatus in question it is possible to record the manufacturing and operating data of one or more packaging machines to each of which the apparatus itself is initially connected also by means of a PC (13) for the processing and storage on the apparatus itself, on the machine and on the database of the same PC, of the construction, operating and maintenance programs of the said machine, all being provided to ensure that during operation of the machine, when the apparatus is reconnected to the machine itself and activated, through the verification programs displayed by it, it is possible to check the functionality of the machine, identify its anomalies and know the possible remedies for repair, being the different information of the intervention memorized on the apparatus and on the computer of the machine and being foreseen that the apparatus is subsequently col linked to the PC (13) of the maintenance center, which is connected in addition to a printer and a monitor (113-213), to a different type of database (33-34-35) where the intervention data are transferred carried out which are then stored, processed and used for different purposes 5 10 15 20 25 30 35 40 45 50 55 60 65 5 9 CH 691 940 A5 for which the system was designed, for example for technical purposes, for statistical purposes, for administrative purposes and for the warehouse for the assistance and supply of spare parts, while the device registration memory is reset for subsequent intervention . 2. Apparatus according to claim 1, characterized in that it remains connected to the packaging machine operating in the same place, even during its normal operation and via modem (82-182) the same apparatus can, if necessary, be connected via telephone line (81), to a PC (13) installed at a maintenance center, to monitor the machine, identify any anomalies remotely, remotely suggest remedies for minor repairs, transmit programs to the machine processor updated or modified or alternative, for example to allow the same to continue operating in emergency situations, and to acquire the maximum information in anticipation of a specialized maintenance intervention carried out by personnel authorized by said remote control unit. 5 10 15 20 25 30 35 40 45 50 55 60 65 6