DE102009000938A1 - Plastic processing machine i.e. extruder machine, controlling method for use during production of e.g. pipe, involves reading required machine parameters from database and transmitting data to plastic processing machine - Google Patents

Abstract

The method involves continuously detecting material data by a detection unit (3) before processing a material (2) e.g. argil, ceramics, rubber, natural rubber or thermoplastic, in a plastic processing machine (1). Specific values are determined by data comparison and/or mathematical processing of the detected material data. Required machine parameters are read from a database (4) and transmitted to the plastic processing machine. The machine parameters are manually modified at an input location. The material data is selected from a group consisting of material type, material composition, material shape, material color, material temperature and material humidity.

Description

The The invention relates to a method for controlling a plastic processing machine dependent on of the discontinued material, wherein at least one detection unit continuous material data is collected before the material of a Processing in the plastic processing machine is subjected.

The increasing quality requirements and the requirement for minimal rejects to the products require an early Intervention in the process parameterization, for example in extruder machines and their successor units. To solve these requirements are Procedures using neural networks, neuro-fuzzy, a self learning, correcting and regulating system, map, known. There are also different control algorithms and combinations for Optimization of the process behavior used as well as approaches after the theory of evolution.

typically, become a variety of materials on a production machine processed, to which the process parameters are adapted. It but has about it It also showed that on a production plant the input material data from batch to batch and manufacturer to manufacturer of a dispersion subject and that environmental influences such as raw material form, temperature and material moisture disturb the process and thus optimal process control to produce the required quality not without interference To ensure users is. In particular is used in the processing of recycled materials and recyclates the optimal setting of a process without the exact knowledge the material composition, almost impossible.

task The invention is therefore to provide a method by means of the influence of the material, that of the plastic processing machine is automatically taken into account.

The solution the object is in connection with the preamble of the claim 1, characterized in that by means of the detected material data by Data comparison and / or mathematical processes one or more Characteristics are determined and then based on the determined Characteristics The required machine parameters from a database read out and transferred to the plastic processing machine become.

It Thus, in the continuous process, the incoming specific Material data recorded and evaluated accordingly. Based on this recorded data can be the appropriate control, for example, via a PLC or similar Control is realized, look in a knowledge database, around the for to query this material data required machine parameters and to the plastic processing machine.

Of the The idea is therefore based on known detection systems and existing ones Databases in a suitable way to combine that a largely automatic adjustment and correction of the setting of a machine can be done. The recording systems determine on the basis of the recorded Data z. For example, a kind of index associated with a particular record number fits in the database. If this record is not found, it will determined by an algorithm or other mathematical system, which nearby data record is read out and its parameters transmitted to the machine control becomes. Do the data / parameters read out too much from the desired one? Characteristic values, a warning can be issued. Here is one Warning in the display or as a light or in any acoustic form conceivable. The machine personnel can then observe the product result, Correct the parameters manually and, if necessary, as a new record Save with a new characteristic value. Will be at a later date recorded analog data, the system then finds the desired Record with the machine parameters in the database.

On In this way, the system is successively enriched with additional data and evolves into an independent expert system.

It is thus possible For example, in extremely cold material, the temperature of a To increase extruder and thus without the influence of the operator the required degree of melting to reach. As another example, the speed of the extruder could be be adapted according to the detected form of the material, because with a round granule or a flake-shaped recyclate other extruder speeds are meaningful.

The proposed method is suitable both for the acquisition of the material data from typical plastics such as thermoplastics as well as clay, ceramics, Rubber, rubber, organic compounds, composites, biomaterials or metals and the like Materials.

The detection unit, which may be, for example, a material sensor, detects both the type of material and material color, the composition of the material, the shape of the input material, the temperature and the humidity. Certainly it is also conceivable to be able to record further material data. As a sensor can also be a near-infrared spectroscope and / or humidity and temperature sensors are used. The data acquisition does not necessarily have to take place via a detection unit, it is also possible for several sensors to transmit the data to the process control.

In This control unit, either directly in the plastic processing machine is integrated, but also within a company, in a data center or otherwise can be accommodated, now the material data processed. Dependent on This determined material data is stored in a knowledge database already stored machine parameters retrieved and, as already above described, transmitted to the plastic processing machine. For example, processing can be done by identifying a specific measure for this Material data can be achieved, in which case using this indicator the machine parameters are queried in the knowledge database. For example, the determined code differs from a stored one Key figure value in the database, so decides a deposited mathematical algorithm, which of the adjacent data sets as Machine parameter is read out.

The Machine parameters transmitted to the plastic processing machine are output in parallel in a suitable manner, which for example via a Display or touch screen on the machine.

Over a Input location, which, for example, the touch screen field on the machine can be, it is possible to manually correct the machine parameters. This may be required if the desired Result is not yet optimal and a correction is required. This corrected data can then as a new record of machine parameters in the knowledge base be stored and stand the system for Follow-up processes available.

During the Processes within plastics processing can record further measured values which are also transmitted to the process control. Because of this Method is it possible the machine parameters supplied by the database in the frame to check a result control and thus individually correcting individual or all parameters. Of course, these can Correction values are stored as new values in the database.

It So is the comparison of the measured data with a knowledge base for optimal automatic process parameterization and control the plastic processing machine performed. Suitable for the parameterization Process data are z. B. torque and speed of the main engine and / or additional power take-offs and the temperature profile of the process unit and the tool as well as the melt data. Furthermore, it is conceivable, for example in the extrusion downstream of the extruder calibration units optimal in the cooling and Parameterize pressure behavior. The knowledge database is therefore for all Extrusion process of mono- and multi-layer extrusion designed. As mentioned above The knowledge base can be integrated both in the extruder control be available as well as centrally on an in-house server and single and / or multiple extruder machines or plastic processing machines operate simultaneously.

On Basis of the interaction of knowledge database, acquisition of input material data and control, an active processing recommendation is achieved, which enables the operator to complete the processing process optimally adjusted. Based on the learned processing recommendations is the successively trained system shown here bit by bit able to independently process to lead optimally.

Based on an extrusion line, the method will be explained by way of example in a figure. The figure shows a plastic processing machine 1 , the example here as an extruder 6 is shown, which is a material feed hopper 9 having. The extruder 6 has a drive motor 7 and one on the extruder 6 arranged tool 10 , In the material feed hopper 9 becomes the material 2 given up. In this area of the material task is the registration unit 3 arranged. The registration unit 3 transmits the acquired material data to a computer unit, which is shown here by the dashed line. The data flow is indicated by the arrow from the capture unit 3 shown to the computer unit. Within the computer unit are now through the process control 5 in connection with the database 4 determined by suitable mathematical processes, the required machine parameters. The computer unit transmits the read-out machine parameters to a display 11 and the plastic processing machine 1 , The three double arrows between the plastic processing machine 1 and the computer unit in turn identify the possibility of data exchange, since, as described above, also return values from the processing process can influence the process control. About the display 11 , which can act as an input device at the same time, correction values or of course completely new records in the knowledge base 4 be entered.

Using the example of this extruder line, for example, a second material or product sensor may be placed before the shaping and / or in the succession in order to provide feedback between the pro product properties and the plasticizing or conditioning process. For example, the gloss level of the product could be determined by the second material sensor and returned to the controller. This could in turn be used to control the nozzle heater to automatically set or change the previously defined gloss of the product.

Here So a system is shown that is through experience and reaction the user and experts trained on different material properties becomes. The process parameters thus found are used as data sets in stored in a database and can be recalled at any time. In Combination with a material condition detection is thus an instantaneous intervention possible in the process. It can Processes for pipe, profile, flat films, sheets, granules, Blown film production, but also injection molding and compounding machines be set optimally.

• • Mit der vorgeschlagenen Erfindung kann die kontinuierliche Erfassung der in den Extruder bzw. die Plastifiziereinheit einlaufenden spezifischen Materialdaten durch einen Materialsensor, der die Messergebnisse auflöst nach Materialtyp, -zusammensetzung, -form, -temperatur und -feuchte, umgesetzt werden. Typisch für diese Anwendung ist z. B. bei Kunststoffen der Einsatz von Nahinfrarot-Spektroskopie, von Feuchte- und Temperatursensoren. Erfasst werden können Tone, Keramik, Gummi, Kautschuk, Thermoplastische Polymere, organische Verbindungen, Verbundwerkstoffe, Biowerkstoffe und Metalle.
• • Weiterhin ist der Abgleich der Messdaten mit einer Wissensdatenbank zur optimalen automatischen Prozessparametrierung und -steuerung der Extrudermaschine realisiert. Optimale Prozessdaten sind z. B. Drehmoment und Drehzahl des Hauptmotors oder/und weiterer Nebenantriebe sowie das Temperaturprofil der Verfahrenseinheit und des Werkzeugs. Weiterhin ist denkbar, z. B. die dem Extruder nachgeschalteten Kalibriereinheiten optimal in dem Kühl- und Druckverhalten zu parametrieren.
• • Die Wissensdatenbank ist ausgelegt für alle Extrusionsverfahren der Mono- und Mehrschichtextrusion. Die Wissensdatenbank kann sowohl in der Extrudersteuerung integriert sein als auch zentral auf einem firmeninternen Server zur Verfügung stehen und einzelne oder/und mehrere Extrudermaschinen gleichzeitig bedienen.
• • Eine aktive Verarbeitungsempfehlung auf Basis der Interaktion von Wissensdatenbank und Steuerung, die den Bediener in die Lage versetzt, den Verarbeitungsprozess zu optimieren, ist umgesetzt.
• • Darüber hinaus ist es denkbar, einen zweiten Material- bzw. Produktsensor vor der Formgebung oder/und in der Nachfolge zu platzieren, um eine Rückkopplung zwischen den Produkteigenschaften und dem Plastifizier- bzw. Aufbereitungsprozess zu bekommen. Beispielsweise könnte der Glanzgrad des Produktes, durch den zweiten Materialsensor bestimmt und an die PLC weitergegeben, dazu genutzt werden, um die Düsenheizung so zu steuern, um den im Vorfeld definierten Glanz des Produktes automatisch einzustellen.

In summary, therefore, as already mentioned above, mentioned again:

• With the proposed invention, the continuous detection of the specific material data entering the extruder or the plasticizing unit can be implemented by a material sensor which dissolves the measurement results according to material type, composition, shape, temperature and moisture. Typical of this application is z. As in plastics, the use of near-infrared spectroscopy, of humidity and temperature sensors. Clays, ceramics, rubber, rubber, thermoplastic polymers, organic compounds, composites, biomaterials and metals can be included.
• • Furthermore, the comparison of the measured data with a knowledge database for the optimal automatic process parameterization and control of the extruder machine is realized. Optimal process data are z. B. torque and speed of the main engine and / or other auxiliary drives and the temperature profile of the process unit and the tool. Furthermore, it is conceivable, for. B. the parameters downstream of the extruder calibration units optimally in the cooling and pressure behavior.
• • The knowledge database is designed for all extrusion processes of mono- and multi-layer extrusion. The knowledge database can be integrated into the extruder control as well as centrally available on a company-internal server and serve individual or / and several extruder machines simultaneously.
• • An active processing recommendation based on the knowledge database and control interaction that enables the operator to optimize the processing process has been implemented.
• In addition, it is conceivable to place a second material or product sensor before shaping or / and in succession in order to obtain a feedback between the product properties and the plasticizing or conditioning process. For example, the gloss level of the product, as determined by the second material sensor and passed to the PLC, could be used to control the nozzle heater so as to automatically adjust the pre-defined gloss of the product.

1

Plastic processing machine

2

material

3

acquisition unit

4

Database

5

process control

6

extruder

7

Drive from 6

8th

Temperature control of 6

9

Material hopper

10

Tool

11

display

Claims (8)

Method for controlling a plastic processing machine ( 1 ) depending on the discontinued material ( 2 ), whereby at least one registration unit ( 3 ) continuously recording material data before the material is processed in the plastic processing machine ( 1 ), characterized in that one or more characteristic values are determined by means of the acquired material data by data comparison and / or mathematical processes, and then the required machine parameters are determined from a database (e) on the basis of the determined characteristic value (e). 4 ) and sent to the plastic processing machine ( 1 ) be transmitted. Method according to claim 1, characterized in that that if there is no characteristic value in the database using an algorithm the one to choose Record is determined. Method according to claim 2, characterized in that that at variance of the selected Record of the determined according to Characteristic value desired Record a visual and / or audible indication is triggered. Method according to claim 1, 2 or 3, characterized that the transferred Machine parameters are output / displayed in a suitable manner. Method according to claim 4, characterized in that that over an entry point the machine parameters are changed manually can. Method according to one of the preceding claims, characterized in that values recorded via measuring means within the plastics processing process are transmitted to the process control ( 5 ) and, depending on these values, a correction of the machine parameters is made possible. Method according to one of the preceding claims, characterized characterized in that as material data, for example, data such as Material type, composition, shape, color, temperature and / or moisture are detected. Method according to one of the preceding claims, characterized characterized in that the collection of material data for materials such as clay, ceramics, rubber, rubber, thermoplastics, composites and the like possible is.