EP2808292B1 - Système de maintenance prédictif pour une machine de remplissage - Google Patents

Système de maintenance prédictif pour une machine de remplissage Download PDF

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Publication number
EP2808292B1
EP2808292B1 EP14001721.1A EP14001721A EP2808292B1 EP 2808292 B1 EP2808292 B1 EP 2808292B1 EP 14001721 A EP14001721 A EP 14001721A EP 2808292 B1 EP2808292 B1 EP 2808292B1
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EP
European Patent Office
Prior art keywords
filling
unit
control module
units
machine
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Not-in-force
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EP14001721.1A
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German (de)
English (en)
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EP2808292A1 (fr
Inventor
Michele Montanari
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Sidel SpA
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Sidel SpA
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Publication of EP2808292A1 publication Critical patent/EP2808292A1/fr
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Publication of EP2808292B1 publication Critical patent/EP2808292B1/fr
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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B67—OPENING, CLOSING OR CLEANING BOTTLES, JARS OR SIMILAR CONTAINERS; LIQUID HANDLING
    • B67C—CLEANING, FILLING WITH LIQUIDS OR SEMILIQUIDS, OR EMPTYING, OF BOTTLES, JARS, CANS, CASKS, BARRELS, OR SIMILAR CONTAINERS, NOT OTHERWISE PROVIDED FOR; FUNNELS
    • B67C3/00—Bottling liquids or semiliquids; Filling jars or cans with liquids or semiliquids using bottling or like apparatus; Filling casks or barrels with liquids or semiliquids
    • B67C3/007—Applications of control, warning or safety devices in filling machinery

Definitions

  • the present invention relates to a predictive system and method for a filling machine, designed for filling containers with a product, in particular for predictive fault analysis and maintenance.
  • a system comprising a feed line for feeding a succession of empty bottles to a filling machine, in turn comprising a filling rotating wheel (so called "carousel”), carrying a number of filling units.
  • the filling units are mounted to rotate continuously about a longitudinal axis, engage the empty bottles, fill the bottles with the product, and then feed the bottles to a capping machine, which is connected to the filling machine by at least one transfer wheel and closes the bottles with respective caps.
  • Figure 1 schematically shows a known filling machine, denoted as a whole with 1, for filling liquid into containers 2, for example glass bottles or aluminum cans.
  • Filling machine 1 comprises a conveying device, including a carousel 4, which is mounted to rotate continuously (anticlockwise in Figure 1 ) about a substantially vertical longitudinal axis A.
  • the carousel 4 receives a succession of empty containers 2 from an input wheel 5, which is coupled to carousel 4 at a first transfer station 6 and is mounted to rotate continuously about a respective vertical longitudinal axis B, parallel to axis A.
  • the carousel 4 releases a succession of filled containers 2 to an output wheel 8, which is coupled to carousel 4 at a second transfer station 9 and is mounted to rotate continuously about a respective vertical longitudinal axis C, parallel to axes A and B.
  • Filling machine 1 comprises a number of filling units 10, which are equally spaced about axis A, are mounted along a peripheral edge of carousel 4, each in a corresponding slot or seat 11 of the carousel 4, and are moved by the same carousel 4 along a path P extending about axis A and through transfer stations 6 and 9.
  • Each filling unit 10 is designed to receive at least one container 2 to be filled, and to perform, during its rotation along path P, a number of filling operations according to a filling "recipe", in order to fill the container 2 with a desired fluid or combination of fluids (e.g. in case of carbonated liquids).
  • the filling unit 10 is configured to engage the container 2, at an opening of a neck 2' thereof, and includes one or more fluidic conduits (not shown), which are designed to selectively couple the container 2 to one or more feed devices.
  • Each filling unit 10 also comprises at least one flow regulator device (not shown), designed to define one or more filling passages communicating with the opening of the container 2, and including at least a filling valve, operable to selectively open the filling passage(s) during filling of the container 2.
  • Each filling unit 10 is moreover provided with an electronic board (not shown), including suitable circuitry to control its operation, and operatively coupled to a supervisor unit 14 of the filling machine 1, e.g. including a PLC (Programmable Logic Controller).
  • Supervisor unit 14 also provides an HMI (Human Machine Interface) towards an operator, including suitable input and display means, in order to allow the operator to check and control the operation of the filling machine 1.
  • HMI Human Machine Interface
  • maintenance of the filling units in the filling machine is based on a total number of working hours or working cycles performed by the same filling units; constituent elements are replaced, when a preset upper threshold is reached for these operating parameters.
  • the aim of the present invention is consequently to solve, at least in part, the problems previously highlighted, and in general to provide an improved solution for monitoring the correct operation of a filling machine and for maintenance thereof.
  • One aspect of the present solution provides an automated and computerized system for monitoring the operation of filling units in a filling machine, and for predicting faults in view of a predictive maintenance.
  • each filling unit is continuously monitored, by acquiring operating parameters during its operation, and a predictive algorithm is executed based on the acquired operating parameters, in order to predict the occurrence of faults, and schedule maintenance or replacement for the same filling unit before the faults occur.
  • Figure 2 shows an automated predictive maintenance system according to the present solution, denoted as a whole with 20, which is operatively coupled to a filling machine 1 in a manufacturing plant; for example, filling machine 1 may be made as discussed with reference to figure 1 , so that same reference numerals are used again to denote similar elements.
  • System 20 includes an image acquisition unit 22, e.g. a CCD camera or similar device, arranged at the filling machine 1, in such a manner as to be able to read a univocal coded sign 23, e.g. a so called "datamatrix", a QR code, a barcode, placed on each filling unit 10 of the filling machine 1.
  • image acquisition unit 22 is fixed to a supporting structure 24, facing the carousel 4 of the filling machine 1.
  • System 20 further includes a control module 25, provided with a processing unit 26, such as a CPU, a controller or a microcontroller, suitably programmed in order to be able to execute the operations that will be discussed in detail in the following.
  • a processing unit 26 such as a CPU, a controller or a microcontroller, suitably programmed in order to be able to execute the operations that will be discussed in detail in the following.
  • Control module 25 is provided with a first interface 27, operatively coupled to the processing unit 26, and configured to provide wired or wireless communication with the image acquisition unit 22, in order to allow the processing unit 26 to receive data acquired by the same image acquisition unit 22.
  • processing unit 26 is provided with information regarding the association between each seat 11 of the filling machine 1 and the specific filling unit 10, which occupies the same seat 11. As will be clarified in the following, these information allow to closely monitor the performance of the filling units 10 in relation to the position along the carousel 4, and to properly schedule maintenance and replacement of those specific filling units 10 that are considered to be liable to faults.
  • control module 25 is provided with a second interface 28, operatively coupled to supervisor module 14 of the filling machine 1, and configured to provide wired or wireless communication therewith, so as to acquire specific operating data relating to the operation of filling units 10, during execution of each filling recipe or each filling cycle.
  • the acquired operating data include at least the following operating parameters:
  • control module 25 acquires, through second interface 28, general operating data relating to the operations of each filling unit 10, and in particular relating to the number of working hours, working cycles performed, number of liters of filled liquid, number of CIP - Cleaning in Place - processes undergone by the same filling unit; as it is known, during a CIP process, dummy bottles are coupled to the filling units 10 and a sanitizing liquid is flown through the filling machine, in order to perform cleaning thereof.
  • Control module 25 may also include a display and user interface unit 29, coupled to processing unit 25, allowing an operator to interact with the same control module 25 and to display information (e.g. data and/or plots).
  • a display and user interface unit 29 coupled to processing unit 25, allowing an operator to interact with the same control module 25 and to display information (e.g. data and/or plots).
  • System 20 also includes a storage unit 30, operatively coupled to control module 25 and storing a central database DB.
  • Central database DB includes a number of records, each related to a different filling unit 10, whose univocal coded sign 23 has been identified via image acquisition unit 22.
  • each record 32 of central database DB includes:
  • image acquisition unit 22 is required to be located at the site of the filling machine 1, the physical location of both the control module 25 and the storage unit 30 is independent from the site of the same filling machine 1, and may be local or remote with respect thereto; also, the specific location of the control module 25 may differ from the location of the storage unit 30.
  • control module 25 may be provided with an own storage memory (not shown in Figure 2 ), storing a replica of the whole, or a part of, central database DB, which may be conveniently synchronized and linked to the same central database DB (in any known manner, here not discussed in detail).
  • a portable electronic apparatus such as a PDA, a laptop, a smartphone, a tablet, with wireless data communication capability, may also communicate with the storage unit 30 through an internet connection and a web interface, in order to access the stored data for further analysis or processing.
  • An operator may interact with both control module 25 and, in case, the above portable electronic apparatus, to access data stored in the central database DB, and e.g. display information or plots of relevant data and information.
  • Control module 25 continuously monitor operation of each filling unit 10 in the filling machine 1, as shown in step 40.
  • control module 25 acquires filling operating parameters (both the general and the specific operating parameters previously discussed).
  • Control module 25 then processes, at step 42, the acquired data in order to check if the filling unit 10 is working properly.
  • control module 25 executes a suitable comparison between the acquired operating parameters for each filling unit 10 and the characterization data for the same filling unit 10 stored in the central database DB, and between the same acquired operating parameters and the operating parameters acquired for the other filling units 10 of the whole filling machine 1, in order to determine if the operation of the filling unit 10 deviates from its standard, normal, operation and/or from the operation of the other constituent elements of the filling machine 1.
  • Control module 25 is able to retrieve from central database DB in storage unit 30 any data that may be required for the above comparative analysis.
  • control module 25 determines, at step 44, that the operation of the filling unit 10 is "normal", i.e. in line with what was expected based on the characterization data and the operation of the other constituent elements of the filling machine 1, then a normal monitoring mode is followed, step 45, according to which acquired operating data are stored in the central database DB, with a first preset storage frequency, for example once a day.
  • Control module 25 updates in the related field of the record 32 in the central database DB the general operating data, relating to the number of working hours, number of working cycles performed, number of liters of filled liquid, number of CIP processes performed by each filling unit 10.
  • control module 25 stores in the related field of the record 32 in the central database DB the specific operating data for the filling units 10, determined during the monitoring time interval pertaining to the current storage operation (i.e. during the time interval elapsed since the last storage operation).
  • control module 25 calculates, for each filling unit 10, the average of the relevant operating parameters (e.g. filing time FT, tail time TT, KT, FFC), which have been acquired during the monitoring time interval.
  • relevant operating parameters e.g. filing time FT, tail time TT, KT, FFC
  • Control module 25 further determines, for the same relevant parameters, machine-average values, as the average calculated on the filling units 10 of the whole filling machine 1 (in particular, as the average of the average values for the various filling units 10, computed after each machine cycle); control module 25 also calculates, for each filling unit 10, the deviation ⁇ of the value of the respective relevant parameters with respect to the determined machine-average values.
  • filling machine 1 is considered as a "batch", as a single entity including the various filling units 10; this may be advantageous to provide to the operator overall information regarding the operation of the whole machine.
  • the specific operating data that are stored in the central database DB, at each storage operation, are therefore the average values of the relevant operating parameters calculated for the various filling units 10, associated to the deviation ⁇ with respect to the machine-average values, and the same machine-average values (wit the result of a considerable saving in the occupation of storing resources).
  • control module 25 determines, at above step 44, that the operation of the filling unit 10 is "anomalous", i.e. not as expected, then an anomaly monitoring mode is followed, at step 46, according to which acquired operating data are stored in the central database DB with a second storage frequency, higher than the first storage frequency, for example once every hour or half an hour.
  • the value of the second storage frequency may also vary dynamically, based on the amount of deviation of the determined operating condition from the "normal" state, or progressively with time after the determination of the anomalous operating condition is made.
  • the general effect is that of achieving a more accurate monitoring of the filling units 10, when doubts about their correct operation arise.
  • control module 25 is configured to process the acquired data with a predictive algorithm, at step 48, in order to predict possible occurrence of a fault or a malfunction, so that suitable alarms may be activated and suitable control actions performed (such as refurbishment or replacement of the faulty filling unit).
  • control module 25 is configured to execute any suitable predictive strategy, based on the acquired data relating to the operating parameters of the filling units 10, and in particular based on: the performance of each filling unit 10, considered independently, and/or in connection with the operation of the whole filling machine 1 and/or with the stored characterization data for the same filling unit 10; the deviation of the operation of each filling unit 10 with respect to the average operation of the other filling units 10 in the filling machine 1; the wearing state of the same filling unit 10, determined based on the information about the working cycles and hours already performed.
  • Control module 25 is thus configured to monitor the state of degradation of the filling units 10, with the passing of time and filling cycle by filling cycle, so as to timely and reliably predict the occurrence of possible faults, and also to determine the causes of the malfunction.
  • the control module 25 also suggests, at step 49, a suitable time to execute maintenance of the filling machine 1, in order to avoid errors and malfunctions, and particularly the number and positions (in terms of the occupied seats 11) of the filling units 10 that are to be replaced in the filling machine 1.
  • the same control module 25 is also able to suggest a replacement unit for each filling unit 10 that is to be replaced, in the form of a list, the so called "rotation kit". For example, a list of replacement filling units 10, whose data are present in the central database DB and whose characteristic may suite the operation of those to be replaced, is suggested to the operator, in view of the scheduled maintenance operation.
  • control module 25 or other portable electronic apparatus accessing the central database DB and running suitable software programs, to access data stored in the central database DB, and e.g. display information or plots.
  • Figure 5 shows an exemplary plot relating to the filling time FT for a filling unit 10, showing the progressive lengthening of the same filling time.
  • the plot shows a first region of normal operation, denoted with R 1 , followed by a region of anomalous operation, denoted with R 2 , where frequency of storage operations is intensified, to closely monitor wearing of the component (as shown by the filling time FT crossing threshold TH).
  • the plot also shows the filling unit 10 returning to a normal operating condition, after maintenance has been performed, at region denoted with R 3 .
  • Figure 6 shows a further plot, which may be displayed by control module 25, showing, in a histogram format, minimum, maximum and average values for the filling time FT of a given filling unit 10, compared to average values for the other filling units 10 in the filling machine 1.
  • Figure 7 shows still a further plot, which may be generated by the control module 25, allowing a direct and immediate visual perception of the operating condition of the filling units 10 in the filling machine 1, with respect to monitored parameters filling time FT and tail time TT.
  • each filling unit 10 is represented as a "ball", in a two-dimensional plot where average filling time FT values are represented along the x axis, and average tail time TT values are represented along the y axis.
  • Ball color denotes the deviation ⁇ for the filling time FT
  • the ball dimension i.e. its radius
  • the deviation ⁇ for the tail time TT with respect to the machine-average values.
  • the number associated to each ball refers to the particular seat 11 where the related filling unit 10 is placed. In this exemplary representation, balls with deeperhue color and greater size indicate a possible malfunction of the related filling units 10.
  • Numerical values for the relevant operating parameters may also be easily obtained, for each of the depicted balls (as shown in Figure 7 for ball number 29).
  • Figure 8 shows information that may be displayed by control module 25, including values for the filling time FT and tail time TT operating parameters.
  • values computed on all the filling units 10 in the filling machine 1 are displayed (in other words, considering the filling machine 1 as a "batch", as a single entity): in particular, an average value, a minimum value and a maximum value are displayed for each relevant operating parameter.
  • a "batch" may be exploded to get specific information about each filling unit 10 in the filling machine 1, with respect to the same considered operating parameters, at the particular storing operation, in particular relating to the deviation with respect to the machine-average values and the characterization values.
  • Each filling unit 10 in the filling machine 1 is fully exploited, as long as its operation remains within the boundaries of a normal operating condition, independently from the number of working hours or cycles already performed (in other words, a filling unit 10 is not replaced based only on the working lifetime, but based on its actual functionality, determined from actual measurements of relevant operating parameters).
  • further analysis of the acquired data may be performed to detect anomalous operations and to predict faults and malfunctions of the filling units 10 in the filling machine 1.

Landscapes

  • Filling Of Jars Or Cans And Processes For Cleaning And Sealing Jars (AREA)

Claims (4)

  1. Système automatique (20) de maintenance prédictive d'une machine de remplissage (1), comprenant un nombre d'unités de remplissage (10) conçues pour engager au moins un récipient respectif (2) pour réaliser le remplissage de celui-ci avec un produit de remplissage,
    comprenant un module de commande (25) qui est couplé de façon opérationnelle à la machine de remplissage (1) et est configuré pour:
    acquérir des données de fonctionnement relatives à la performance des unités de remplissage (10) pendant les opérations de remplissage; et
    traiter les données de fonctionnement acquises afin de prédire l'occurrence d'une défaillance dans une ou plusieurs des unités de remplissage (10), et comprenant en outre une unité de stockage (30) stockant une base de données (DB) et couplée de façon opérationnelle au module de commande (25); chaque registre (32) de la base de données (DB) étant associé à une unité de remplissage (10) de la machine de remplissage (1) et stockant un sous-ensemble des données de fonctionnement acquises pour l'unité de remplissage (10), ledit module de commande (25) étant configuré pour traiter les données de fonctionnement acquises afin de déterminer un état de fonctionnement normal ou anormal de l'unité de remplissage (10);
    caractérisé en ce que le module de commande (25) est configuré pour entraîner le stockage du sous-ensemble de données de fonctionnement acquises à une première fréquence de stockage, dans le cas où un état de fonctionnement normal est déterminé, et à une deuxième fréquence de stockage, dans le cas où un état de fonctionnement anormal est déterminé, la deuxième fréquence de fonctionnement étant plus élevée que la première fréquence de fonctionnement.
  2. Système selon la revendication 1, dans lequel le module de commande (25) est configuré pour:
    exécuter un algorithme prédictif afin de prédire la défaillance de la ou des unité (s) de remplissage (10) ; et
    traiter les données de fonctionnement acquises pour une unité de remplissage donnée (10) par rapport à des données de fonctionnement correspondantes acquises pour d'autres unités de remplissage (10) dans la machine de remplissage (1), dans le but de déterminer un état de fonctionnement normal ou anormal de l'unité de remplissage donnée.
  3. Système selon la revendication 1 ou la revendication 2, dans lequel le module de commande (25) est configuré pour:
    traiter les données de fonctionnement acquises pour l'unité de remplissage donnée (10) en relation avec des données de caractérisation pour l'unité de remplissage donnée (10), dans le but de déterminer un état de fonctionnement normal ou anormal de celle-ci; et
    calculer un écart (σ) de l'état de fonctionnement de l'unité de remplissage donnée (10) par rapport aux autres unités de remplissage (10) dans la machine de remplissage (1) et/ou par rapport aux données de caractérisation.
  4. Système selon l'une quelconque des revendications précédentes, dans lequel le module de commande (25) est configuré de manière à programmer une opération de maintenance de la machine de remplissage (1) et à fournir une liste d'unités de remplissage défaillantes (10) devant faire l'objet d'une maintenance, et ledit système comprenant en outre:
    une unité d'acquisition d'image (22) configurée pour imager les unités de remplissage (10) de la machine de remplissage (1) afin de lire un signe codé univoque (23) qui est associé à chacune des unités de remplissage (10),
    une unité de stockage (30) stockant une base de données (DB) et couplée de façon opérationnelle au module de commande (25); chaque registre (32) de la base de données (DB) étant associé à une unité de remplissage (10) de la machine de remplissage (1) et stockant un sous-ensemble des données de fonctionnement acquises pour l'unité de remplissage (10) et le signe codé univoque (23) associé à la même unité de remplissage (10).
EP14001721.1A 2013-05-31 2014-05-15 Système de maintenance prédictif pour une machine de remplissage Not-in-force EP2808292B1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
EP14001721.1A EP2808292B1 (fr) 2013-05-31 2014-05-15 Système de maintenance prédictif pour une machine de remplissage

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
EP13170186.4A EP2808291A1 (fr) 2013-05-31 2013-05-31 Système et procédé de maintenance prédictif pour une machine de remplissage
EP14001721.1A EP2808292B1 (fr) 2013-05-31 2014-05-15 Système de maintenance prédictif pour une machine de remplissage

Related Parent Applications (1)

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EP13170186.4A Previously-Filed-Application EP2808291A1 (fr) 2013-05-31 2013-05-31 Système et procédé de maintenance prédictif pour une machine de remplissage

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EP2808292A1 EP2808292A1 (fr) 2014-12-03
EP2808292B1 true EP2808292B1 (fr) 2015-12-09

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EP13170186.4A Withdrawn EP2808291A1 (fr) 2013-05-31 2013-05-31 Système et procédé de maintenance prédictif pour une machine de remplissage
EP14001721.1A Not-in-force EP2808292B1 (fr) 2013-05-31 2014-05-15 Système de maintenance prédictif pour une machine de remplissage

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP3984942B1 (fr) 2020-10-16 2023-08-09 Krones Ag Dispositif et procédé de traitement d'un récipient à l'aide d'un essai fonctionnel

Families Citing this family (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP3378828A1 (fr) * 2017-03-24 2018-09-26 Sidel Participations Machine de remplissage de récipient ayant une meilleure capacité de stockage et de communication de données
JP7464356B2 (ja) * 2019-05-22 2024-04-09 アサヒビール株式会社 充填状況監視装置及び充填状況監視方法
JP2023101950A (ja) * 2022-01-11 2023-07-24 サントリーホールディングス株式会社 検査装置
DE102022122554A1 (de) 2022-09-06 2024-03-07 Krones Aktiengesellschaft Verfahren zur Steuerung von Prozessen des Behälterhandlings und Behälterbehandlungsanlage zur Produktion, Abfüllung, Handhabung, Verpackung und/oder Förderung von Behältern

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Publication number Priority date Publication date Assignee Title
US4691496A (en) * 1983-01-31 1987-09-08 Peco Controls Corporation Filler line monitoring system
US20070107801A1 (en) * 2005-11-14 2007-05-17 Sidel And Pressco Technology Inc. Bottle filling machine with sensor and method thereof
DE102011006717A1 (de) * 2011-04-04 2012-10-04 Krones Aktiengesellschaft Verfahren zum automatischen Überprüfen einer Getränkeverarbeitungsanlage
DE102011017448A1 (de) * 2011-04-18 2012-10-18 Krones Aktiengesellschaft Verfahren zum Betreiben einer Behältnisbehandlungsanlage mit Störungsdiagnose

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP3984942B1 (fr) 2020-10-16 2023-08-09 Krones Ag Dispositif et procédé de traitement d'un récipient à l'aide d'un essai fonctionnel

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EP2808291A1 (fr) 2014-12-03

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