EP3331766A1

EP3331766A1 - Self-controlling packaging machine and method for same

Info

Publication number: EP3331766A1
Application number: EP16758098.4A
Authority: EP
Inventors: Elmar Ehrmann; Claus Botzenhardt
Original assignee: Multivac Sepp Haggenmueller GmbH and Co KG
Current assignee: Multivac Sepp Haggenmueller GmbH and Co KG
Priority date: 2015-08-06
Filing date: 2016-08-08
Publication date: 2018-06-13
Also published as: CN107848648A; CN108137182B; EP3331764A1; US20180273225A1; CN108137178A; US11021288B2; WO2017021554A1; US11485534B2; CN107848648B; CN108137182A; WO2017021557A1; EP3331767B2; CN107922066B; CN108137178B; EP3331767A1; US20180297730A1; US10843834B2; EP3331764B1; CN107922066A; EP3331765B1

Abstract

The invention relates to a packaging machine (1) which comprises a control unit (2), multiple measuring devices (5), and multiple working units (3) for different processes. The control unit (2) is functionally connected to the working units (3) and to the measuring devices (5), and the measuring devices (5) are configured to detect actual process values (I) at each working unit (3) and forward same to the control unit (2) in order to monitor a process status of each working unit (3). The control unit (2) is designed to produce a program sequence (P) in a self-controlled manner for each working unit (3) and/or in a coordinated manner with respect to the working units (3) by comparing (V) the actual process values (I) forwarded to the control unit from each measuring device (5) with corresponding target process values (S) from a storage unit (7) connected to the control unit, and each working unit (3) functions on the basis of the actual process values (I) detected at the working unit and/or in a coordinated manner according to the program sequence.

Description

Self-controlling packaging machine and method therefor

The present invention relates to a self-controlling packaging machine according to claim 1. Furthermore, the present invention relates to a method of a self-controlling packaging machine according to independent claim 17.

In known packaging machines, the manufacturing process consists of a plurality of individual processes, such as e.g. Closing the chamber, heating, molding, evacuating, fumigating, sealing, opening the chamber, and collapsing safety times to adequately ventilate chambers.

The individual processes are time-controlled, with the individual processes running one after the other, possibly intermittently overlapping or separated by safety time intervals. The respective process times depend in particular on a chamber volume, types of foils, sequences of movements and switching times of valves of the packaging machine and therefore have to be pre-set by the machine operators for each machine equipment as well as for each product to be produced consuming on the operating console of the packaging machine.

The setting of the respective processing times of the packaging machine as well as the coordination of the respective process times on each other requires a very large knowledge of the individual processes by the machine operator, whereby it occurs even with very experienced machine operators that several test procedures are necessary for the packaging machine to the respective process times smoothly to each other get tuned adjusted.

Often, however, there are delays in setting process times of the packaging machine, as a result of which the performance of the packaging machine is significantly reduced.

A known forming station is shown in FIG. 7a. This includes an upper part and a lower part, which is height adjustable by means of a hoist. Between the upper part and the lower part, a heating plate is provided in a mold chamber, which serves for heating a film section to be deformed. Next, pressure and ventilation valves are provided in the upper part and in the lower part, on the one hand to first press the film section against the heating plate and on the other hand to allow pressure forming a packaging tray M. These processes are timed according to a pre-set schedule.

The time-controlled valve circuit is illustrated in FIG. 7b. Section AA shows the main processes hoist open / close, heating and forming. Below in the BB shows pre-set process times that are set by the operator in the packaging machine. Section CC shows the ventilation and pressure valve positions for the top and bottom of the forming station. In section DD, the respective pressure curves are displayed in the upper part and the lower part.

After the forming station has been closed (step A), pressure is generated in the base (step B '). The build up of pressure is timed (step C) and stops when the predetermined time has elapsed. Likewise, a preset heating time of the heating plate expires (step D '). After the heating time has elapsed, the vent valve opens in the lower part (step E ') and pressure is built up in the upper part to form the heated film section (step F'). The build-up of pressure as well as a preset stabilization time for shaping are timed (step G 'and H'). As soon as the stabilization time has expired, the upper ventilation opens (step Γ). Now, a preset safety time expires at the end of the molding process (step J ') before the molding station opens (step K').

The hoist open / close processes are position-controlled and heating and forming are time-controlled in the upper forming station. Therefore, the operator must enter a scheduling plan for the forming station in the controller. When creating the timing plan, the operator gropes through several attempts to a desired packaging result. This approach requires a high level of routine and can only be accomplished by trained personnel.

DE 10 2009 017 638 A1 discloses a packaging machine, to which process times can be adapted by changing boundary conditions. The respective process times depend in particular on the number of products made available to be packaged.

EP 1 316 002 B1 discloses a machine tool whose operating sequence can be regulated on the basis of additional data from a database.

DE 10 2012 005 912 A1 discloses a method for checking the availability of the components used in a packaging line.

DE 10 2006 040 807 A1 discloses a sealing station for a packaging machine, wherein a force sensor is provided in the force flow of the sealing station, which enables quality monitoring in real time during the sealing process.

DE 10 2005 059 312 A1 discloses a packaging machine with a reading unit for reading machine-relevant information of a replacement part used in the packaging machine. EP 1 710 074 A1 discloses a packaging machine with a tool having a sensor chip. Characteristics of the tool read from the sensor chip can be used to set the packaging machine.

DE 20 2010 017 361 U1 discloses a method by means of which the production process of a meat product can be tracked.

WO 00/19278 A1 does not relate to packaging technology but discloses a printing or copying system in which the consumption of printer cartridges is controlled and monitored.

DE 10 2008 024 461 A1 discloses a packaging machine with a processing station control unit which is connected to a central control unit of the packaging machine.

The object of the invention is to provide a packaging machine that can be easily set and operated by the machine operator and is also characterized by increased performance. The task is also to provide a suitable procedure for this. In particular, the packaging machine and the method of the invention should be controllable by input of a few parameters and are suitable for the production of very high quality products in reduced cycle times.

This object is achieved by a packaging machine according to claim 1 or by a method according to independent claim 16. Improved developments of the invention are the subject of the dependent claims.

In contrast to known time-controlled packaging machines, the packaging machine according to the invention and the method for this process are controlled by means of intelligent sensors and control technology. The respective work processes are monitored by sensors and controlled as a function of values detected. In the case of the packaging machine according to the invention, the program sequence of the working units used on it is no longer primarily linked to process times preset by the operator, but is adapted during operation to the current production process, in particular to the measurable process progress of the respective working units. Above all, it monitors how far actual process values have progressed with regard to specified or calculable setpoint process values at the respective work units. On rigid process times, which were previously set manually on the machine manually by the operator, is no longer taken into account, because the respective processes run on the work units as long as one or several target process values are reached, ie, that the respective processes are sensor-controlled.

If anything, the invention uses process times that are automatically retrievable from memory and can be generated based on specific manufacturing parameters relating to the product, tool and / or packaging material. Thus, the packaging machine can be quickly adapted during a tool change and / or a product change, without the operator long time to readjust the packaging machine needed. In the invention, the packaging machine therefore optimally adapts its operation itself.

For this, the packaging machine according to the invention comprises a control unit, a plurality of measuring devices and a plurality of working units for different processes, wherein the control unit is functionally connected to the working units and to the measuring devices. The measuring devices are configured to acquire actual process values at the respective working units and forward them to the control unit in order to monitor a process status at the respective working units. The control unit is designed, by comparing the actual process values forwarded to it by the respective measuring devices with associated desired process values, in particular with an associated target process value range, from a memory connected to it, a program sequence for the respective work units themselves / or manufacture self-controlling with respect to the working units. The respective work units can then function in accordance with the actual process values acquired thereon themselves and / or coordinated with one another in this regard.

Self-controlling in the sense of the invention means that the program sequence on a work unit does not take place according to a preset process time. Rather, the program sequence at a work unit adapts itself to the actual process values acquired therewith and is therefore sensor-controlled. In the invention, the control unit functions as a functional link between the measuring devices and the working units. In this case, the detected actual process values are forwarded by the measuring devices to the control unit, which, with regard to the actual process values, controls the respective program sequences for the working units themselves and / or adapted to each other.

In particular, a process at a work unit can begin when a functionally preceding work unit reaches at least one setpoint process value. In particular, the sequence of the individual work units can be well coordinated. It In the invention, a functional link can be established between the individual working units so that the respective working units can work seamlessly consecutively.

In addition, the invention makes it possible, by means of the actual determination of the process value at the respective work units, to determine the early start of individual work units. This is due to the fact that a certain reaction time is required for the control of the valves and / or for the generation of control signals, which is also called dead time in professional circles. In order to reduce such dead times, in the invention, based on the actual process value determination, at least the operation of a work unit may prematurely, i. certain time before reaching a target process value, to be started. Overall, this leads to time savings because the respective work processes in the process are better coordinated.

The packaging machine according to the invention thus differs substantially from the prior art in that it is no longer time-controlled according to a preset rigid program sequence, i. operated with certain process times for the respective work units. On the contrary, the packaging machine according to the invention, by means of the sensors and control available to it, is able to precisely adapt the respective processes of the working units to the actual process values currently acquired thereon, independently of how long the respective process has already been carried out. The respective processes can be carried out in an optimized manner in terms of economy and can, if appropriate, run in such a coordinated manner that overall larger batch sizes can be produced within shorter cycle times. In addition, it can produce the same quality for all products.

Thus, in contrast to the prior art, the performance of the packaging machine according to the invention no longer depends on the machine operator's ability to adjust but on the technical capabilities of the packaging machine itself, self-directed to the manufacturing process, i. to the currently recorded process values at the work units.

The packaging machine according to the invention has shown to be particularly advantageous for the start phase of a production process because it no longer requires several test runs for optimum setting of the packaging machine. On the contrary, the packaging machine according to the invention makes it possible to produce products optimally from the beginning, because the respective processes at the working units can be controlled immediately by means of the control unit by means of feedback in the process with respect to the actual process values recorded thereon. The fact that in the invention, the packaging machine itself is designed to optimize the processes carried out there, it comes to increased cycle performance, which personnel costs can be reduced.

The packaging machine preferably comprises at least one robot designed as a working unit. This is used in particular as a mounter to be filled packaging. The operation of the robot in the invention can be adapted to the flow of other work units. In particular, accelerations made by the robot arm can be adapted with regard to the progress of other work units on the packaging machine.

According to one embodiment of the invention, the packaging machine may be designed as a deep-drawn packaging machine, a tray sealer, or a chamber belt machine. Since several working processes, in particular in coordination with one another, take place in such packaging machines, the self-controlling feedback can be used particularly performance-enhancing on the basis of the control unit of the packaging machine according to the invention. These packaging machines can then autonomously and automatically regulate their production process, without primarily having to resort to pre-set process working cycle times. In this regard, changeover times can be enormously reduced on such machines, in particular.

In the case of the packaging machine according to the invention, the memory connected to the control unit serves, in particular, as a data reservoir, from which the control unit receives the desired process values, in order to carry out a feedback control of the respective working units as soon as possible for detecting the actual process values.

In particular, it is possible for the memory to be designed as a database, preferably as a knowledge database, which is configured to derive the desired process values for the respective working units with regard to data of a product to be produced by means of the packaging machine. Preferably, the product to be produced, in particular a film specification, a tool type and / or a food product to be packaged, can be called up via an input console of the packaging machine, based on this setting a special set of desired process values by the memory, in particular the database contained therein, the control unit for the manufacturing process can be provided. This would have the advantage that at the start of production the machine operator only selects the product to be produced on the input console of the packaging machine. must choose, in which case the manufacturing process is taken over by the packaging machine self-controlling.

The database can be used in a particularly versatile manner if it is formed as part of a database system, wherein the database system further comprises a database management unit which is configured for bidirectional data exchange between the control unit and the database. By means of the database administration unit, not only can the relevant setpoint process values from the database be ascertained and / or read from the database based on the acquired actual process values at the work units, but moreover also control functions, in particular starting from the control unit at the database, can be carried out that, for example, records stored on the database can be corrected, adapted and / or replaced. The packaging machine according to the invention could then be easily adapted to such a product, for example, in view of a new product which had not previously been produced with it. Updates of the data sets stored in the database could be played for example via a VPN connection, a wireless connection, for example by means of RFID, or from a USB stick to the database.

In the invention, the processes are controlled on the packaging machine in particular by form-, process- and / or film-dependent information. Film-dependent information mainly relates to a drawing depth, a sealing seam width, a final vacuum during sealing, a number of packs, a pack size and / or a mold depth. Process-dependent information is above all a specific molding pressure, a specific sealing pressure, a cutting time, maximum permissible early start times when opening or closing a hoist and / or maximum permissible early start times during film advance. Film-dependent information is in particular a film type, a sealing layer, a film thickness, a sealing layer thickness, a cooling time (stabilization time) in the mold, an ideal heating time, an ideal sealing time, an ideal heating temperature during molding and preheating and / or an ideal heating temperature during sealing. In particular, the control unit is configured to produce the desired process values and / or control signals for the manufacturing process on the basis of the format, process and / or foil-dependent information. The desired process values are preferably based on data of the product to be produced, which for this particular indicate a sealing surface, a sealing pressure, a final vacuum, a type of film and / or a film thickness or a film specification, for example the layer structure.

Preferably, information relating to the film specification can be stored in the database by means of a wireless connection; in particular, the information about the film material can be obtained from an RFID tag attached to the film by means of an RFID tag attached to the film. RFI D reader provided and stored by this in the database.

For each product to be produced, there is preferably a preselection of certain desired process values which are available to the packaging machine during the operation as a result of the process-controlled self-control function. The program sequences at the respective work units are thus adaptable with regard to the predetermined target process values.

Preferably, the desired process values indicate an optimum forming and / or sealing temperature, an optimal sealing and / or forming pressure, and / or at least one stabilization time for a working unit designed as a forming station. Upon reaching the predetermined optimal process value (s), the control unit may decide when to terminate the process at a work unit and start a subsequent process on the same work unit or other work unit to complete the production flow with smooth transitions between the processes Control work units.

According to one embodiment variant, the memory is integrated in the control unit or alternatively exists as an external unit. In the integral design of the memory in the control unit, the memory can be controlled directly via an operating console of the packaging machine, wherein in this variant mainly stored in the memory records can be updated, replaced and / or supplemented by the control panel. In particular, as an external unit, the memory could be operatively connected to a plurality of packaging machines, wherein the respective control units of the plurality of packaging machines may have functional access to the memory executed as an external unit. This is particularly useful when several packaging machines work in parallel in a production hall, where it is not absolutely necessary that the respective packaging machines are each equipped with its own memory. It would also be conceivable that the several packaging machines rely on different data sets of the memory. It would be conceivable that run on the packaging machines different manufacturing processes.

Preferably, the memory is functionally connectable to an external network, wherein the memory via the external network can be updated and / or controlled. It would be conceivable, for example, that a machine operator from his computer workstation records on the external network in which his computer is functionally integrated, plays on the memory. It would also be conceivable that the external network is used by the packaging machine manufacturer to control the memory of the packaging machine, although this already involved with the food packer in the production. Using this variant, any data can be read from the memory, for example, error messages, operating conditions, production data and / or server data.

Preferably, the respective measuring devices comprise at least one force, pressure, displacement, temperature, infrared, ultrasonic, induction, laser and / or moisture sensor. The respective sensors are in particular integrally installed in the working units in order to capture as closely as possible the actual process values present thereon. Preferably, the sensors used continuously detect the respective actual process values during operation of the packaging machine, so that when a desired process value is reached, the controller can react quickly to possibly terminate the process and start a subsequent process.

Preferably, at least one of the working units comprises a movable base and a top including a molding chamber or a sealing chamber therebetween and each having at least one pressure measuring unit. This allows the pressure curves within the upper part and lower part to be monitored during the manufacturing process. The control unit can perform a control of the pressure generation as a function of the pressure curves. The control unit could also control other processes within the molding chamber or the sealing chamber as a function of the pressure profiles.

According to one embodiment, one of the working units of the packaging machine is designed as a forming station comprising at least one heating plate. This serves to heat a foil section guided into the forming station, so that it can then be deformed well. It is advantageous if a function of the heating plate can be controlled based on detected pressure values within the forming station, in particular if a heating time of the heating plate can be called in dependence on a pressure level reached within the forming station.

According to a variant, the forming station comprises a heating chamber and a molding chamber, which are spatially separated from each other. The heating chamber serves as preheating and preferably comprises a lower and an upper heating plate, between which a film section can be clamped. In order to produce a particularly large clamping force, a pressure generator can be arranged above the upper heating plate, in particular an inflatable membrane which can press the upper heating plate downwards. It is conceivable that one of the working units is designed as a sealing station. This can optionally be equipped with a gassing unit to create a desired atmosphere for the product to be sealed.

Preferably, the actual process value is a pressure detected in the work unit, the control unit being configured to end or start at least one work process on or at at least one other work unit when the sensed pressure has reached a predetermined pressure level. The working process may be, for example, a heating or cooling process which takes place according to a heating or cooling time available from the storage. The invention also relates to a method for self-control of a program sequence of a process at different working units of a packaging machine. According to the program sequence, a process and / or a plurality of functionally coordinated processes are performed on the respective work units during operation of the packaging machine, wherein actual process values are detected at the respective work units and forwarded to a control unit of the packaging machine, the control unit sending them to them comparing actual process values with associated target process values and, as a result, independently producing the respective program sequence for the work units themselves and / or with respect to the respective work units and coordinating the operation of the packaging machine based thereon.

The operation of the packaging machine therefore depends on the detected actual process values at the respective working units. Taking into account desired process values for the product to be produced, it is then possible, on the basis of the detected actual process values, to determine by means of the control unit whether the respective process can continue or be interrupted at a work unit and optionally start a subsequent process. The self-control of the packaging machine thus depends, on the one hand, on the sensor system integrally provided on the respective working units and on the other hand on the feedback control function taking into account desired process values, the setpoint process values of the control unit being made available, in particular, by a memory connected to the control unit.

On the basis of the method according to the invention, the respective program sequences of the processes performed on the working units during operation are adapted in view of the actual process values measured thereon. The sequence of processes is no longer time-controlled, but self-controlling as a function of measured and achieved actual process values. The starting of a process at a work unit thus depends in the invention primarily on which actual process values are measured on the process precautionary in the production process and / or on at least one at least partially running working unit. Preferably, the process starts at a work unit when, on a process of the or at least one other work unit that is pre-installed in the production process, the one or more acquired actual process values correspond to the predetermined target process values. Of course, it can also be the case that the respective processes overlap in time, as it were, running parallel to one another or separated from one another over a time interval. It could therefore be that the process of a work unit is already started when one or more specific actual process variables have not yet reached the target process variables on the process pre-attached to this work unit. This can in particular lead to the avoidance of dead times, whereby the clock cycle times can be shortened. With processes which are spaced apart from one another in terms of time, it would be possible for the subsequent process to be started only when a predetermined time interval has elapsed when the target process variable is reached at a process of a work unit.

The respective processes on the working units can therefore be optimized by means of sensors and feedback control even in their course, the respective optimized program flows of the processes also serve for the other processes of the process for optimization, so that the entire program flow of the method of the packaging machine depending on respective processes can be optimized. Embodiments of the invention will be explained with reference to the figures described below. Show it:

1 shows a packaging machine according to the invention in a general schematic representation,

2 shows a thermoforming packaging machine according to an embodiment of the invention,

3 shows a tray sealer according to an embodiment of the invention,

4a a forming station according to an embodiment of the invention,

4b shows a process diagram for the forming station from FIG. 4a,

5a a forming station according to another embodiment of the invention,

5b shows a process diagram for the forming station of FIG. 5a, FIG. 6a shows a sealing station according to an embodiment of the invention, FIG. 6b shows a process diagram for the sealing station from FIG. 6a, FIG. 7a shows a known forming station and FIG

FIG. 7b shows a time-controlled process diagram for the forming station from FIG. 7a.

1 shows a schematic illustration of a packaging machine 1 according to the invention. For controlling the production process, the packaging machine 1 contains a control unit 2. Furthermore, the packaging machine 1 has a multiplicity of working units 3 which are each connected to the control unit 2 by means of a functional connection 4. The work units 3 are workstations that are configured for different processes to thereby produce the desired product. During the manufacturing process, the respective working units 3 are coordinated with each other. In this case, the respective working units 3 can be seen one after the other in succession and / or to a certain extent parallel to one another, i. work overlapping each other.

According to FIG. 1, the packaging machine 1 contains a multiplicity of measuring devices 5, which are respectively installed in the working units 3. The measuring devices 5 are designed to record actual process values I at the respective working units 3. Furthermore, FIG. 1 shows that the respective measuring devices 5 are connected to the control unit 2 via a further functional connection 6. The measuring devices 5 can forward the detected actual process values I to the control unit 2 via the further functional connection 6. This makes it possible to monitor the respective current process states of the working units 3 during the production process by means of the measuring devices 5 used.

Fig. 1 also shows that the control unit 2 is connected to a memory 7. 1, the memory 7 is formed as part of the packaging machine 1, where it could just as well be connected as an external unit to the control unit 2 of the packaging machine 1. The memory 7, which also has a database, is configured to provide target process values S. The desired process values S depend in particular on specific data of the product to be produced. For example, the target process values S could result in view of a film thickness, a type of film, a sealing surface, a sealing pressure, a final vacuum to be evacuated and / or a product to be packaged. For each product to be produced, which essentially consists of the product to be packaged and the packaging thereof, it is thus possible to provide different desired process values S from the store 7. According to FIG. 1, the control unit 2 has access to the desired process values S from the memory 7 via a data connection 8. In particular, the data connection 8 is designed for bidirectional data traffic between the control unit 2 and the memory 7.

Furthermore, FIG. 1 shows that the control unit 2 is designed, by a comparison V of the actual process values I forwarded to it by the respective measuring devices 5, with the associated desired process values S from the memory 7 connected thereto, a program sequence P for the generate respective work units 3. The program sequence P of the respective working units 3 is provided for actuators A designed on the working units 3. The actuators A perform at the respective working units 3 on the product to be produced a special form of work, such as transport, shaping and / or fumigation work.

Based on the detected actual process values I (path, pressure, vacuum, temperature, etc.) as well as the comparison of these with the desired process values S from the memory 7, the control unit 2 according to the invention initiates a functional feedback in order to connect to the To coordinate respective work units 3 provided actuators A selbststeuernd according to the program P produced by it. In this case, the control unit 2 is configured to coordinate the respective program sequences P for the respective actuators A of the working units 3 themselves and / or to control the respective program sequences P in a self-controlling manner in order to ensure a smooth and economic operation of the packaging machine 1.

In particular, according to one embodiment of the invention, the control unit 2 may be configured to control the program flow P of at least one working unit 3 as a function of the progress of another program sequence of at least one other working unit 3. In this case, the control unit 2 could ensure that the program sequence P of at least one work unit 3 is started when a predetermined actual process value I is detected at at least one other work unit 3. The respective program sequences P can thus be coordinated well coordinated with each other, the function of which depends on the respective detected actual process values on the working units 3 and on the functional feedback thereon. The packaging machine 1 according to the invention is thus designed to coordinate the respective program sequences carried out on it in a self-controlling manner, this taking place in particular in real time, without having to set special values or sequences by a machine operator on the packaging machine.

Furthermore, FIG. 1 shows that the memory 7 contains a database system 9, which is preferably equipped with a database 10 and with a database management unit 11. In the Database 10 may be stored for the respective products to be produced records, which are in particular the respective target process values. Equally well, it could be that in the database 10 special product properties are stored, based on which the database management unit 1 1 derives the target process values S.

FIG. 1 also shows that the control unit 2 may be functionally connected to an external network 13 via a wireless data link 12. The external network 13 may be a computer network, from which the control unit 2 can be controlled. Furthermore, the control unit 2 may be configured to be driven from the external network 13 and based thereon to control the memory 7, for example to update and / or supplement the data records stored in the database 10. Optionally, the activation of the memory 7, in particular of the database 10 contained therein, would also be possible via the control unit 2 by means of an operating console 14 provided directly on the packaging machine 15.

2, the packaging machine 1 according to the invention is designed as a thermoforming packaging machine 15. The thermoforming packaging machine 15 has a forming station 16, a sealing station 17, a cross-cutting station 18 and a longitudinal cutting station 19, which are arranged in this working order in a working direction R on a machine frame 20. On the input side is located on the machine frame 20, a feed roller 21, from which a film web 22 is withdrawn. In the area of the sealing station 17, a material reservoir 23 is provided, from which a cover film 24 is drawn off. On the output side, a discharge device 25 in the form of a conveyor belt is provided on the thermoforming packaging machine 15, with which finished, individualized packages 26 are transported away. Furthermore, the thermoforming packaging machine 1 has a schematically illustrated film feed device 27 which grips the film web 22 and transports it further in the working direction R per main working cycle. The film feed device 27 is designed, for example, as a transport chain arranged on one or both sides of the film web 22. Furthermore, FIG. 2 shows an RFID reader 70, 70 'which is configured to acquire information from an RFID tag, not shown, which is fastened on the lower film 22 or the cover film 24. The information read out is in particular slide specifications.

The inventive principle, which was previously described in connection with the generally illustrated packaging machine 1 of FIG. 1, can be applied to the thermoforming packaging machine 15 according to FIG. 2. Without being limited to this, in the thermoforming packaging machine 15 from FIG. 2, in particular the forming station 16 and the sealing station tion 17 as a functionally controlled working units 3, as they were explained in connection with the packaging machine 1 of Fig. 1, in question.

The forming station 16 is particularly well suited for process control according to the invention. This will be explained in more detail below with reference to different embodiments according to FIGS. 4a, 4b, 5a and 5b. Furthermore, in the following, in connection with FIG. 6, it will be described how the inventive principle can be applied to the sealing station 17. Viewed on its own, the sealing station 17 could comprise a multiplicity of working units 3, for example a sealing tool, a gassing tool, an evacuation tool and / or a transport means provided separately for this purpose, which each run according to self-controlling program sequences themselves and / or in adaptation to each other. An embodiment sealing station will be described later in connection with Figures 6a and 6b.

According to the present invention, therefore, the processes carried out in the thermoforming packaging machine 15 at the respective working units 3 are no longer primarily time-controlled, but rather run in a self-controlling, process-oriented manner as a function of actual process values I measured and achieved thereon.

According to FIG. 3, the packaging machine 1 according to the invention is designed as a tray sealer 28. The inventive principle of the self-controlling packaging machine 1 previously described in connection with FIG. 1 can also be applied to the tray sealer 28.

FIG. 4a shows the forming station 16 according to an embodiment variant. The process mode of the molding station 16 shown in FIG. 4a is shown in FIG. 4b.

The forming station 16 from FIG. 4 a comprises a lower part 32 and an upper part 33. Between the lower part 32 and the upper part 33 is formed a forming chamber 34 for forming packaging troughs M. The lower part 32 is connected to a hoist 35, which supports the lower part 32 in height-adjustable manner relative to the upper part 33. In the lower part 32, a lower pressure valve 36 and a lower (loading) vent valve 37 are provided. In the upper part 33, an upper pressure valve 38 and an upper (loading) vent valve 39 are provided.

FIG. 4a also shows that a lower pressure gauge 40 is provided in the lower part 32 as a measuring device 5, and an upper pressure gauge 41 is provided in the upper part 33. The lower and upper pressure gauges 40, 41 are functionally connected to the control unit 2 of the packaging machine 1.

In addition, according to Figure 4a, a heating plate 42 is disposed within the mold chamber 34. Below the heating plate 42, a film portion 43 is positioned, which is clamped between the lower part 32 and the upper part 33. In the molding chamber 34, first of all the film section 43 heated by means of the heating plate 42 and then brought by means of suitable pressure generation and / or vacuum generation within the mold chamber 34 in a desired shape to produce the packaging trays M. This will be described in more detail with reference to FIG. 4b.

FIG. 4b shows a process diagram 44 for the inventive process-controlled process mode of the molding station 16 depicted in FIG. 4a. The process diagram 44 shows in a vertical arrangement main processes H, process times Z, a valve control sequence VS and pressure profiles D which are process-controlled at the forming station 16 for producing packaging trays M. to each other. In a horizontal arrangement, the process diagram 44 is divided in time into process blocks I to IV.

In process block I, the forming station 16 closes the film section 43 between the lower part

32 and the upper part 33 a. The hoist 35 moves to the lower part 32 relative to the upper part

33 from an open position to a closed position (step a). The lower vent valve 37 is brought to a closed position (step b).

In process block II, the forming station 16 is closed. Process block II involves heating the clamped film section 43 to subsequently easier to deform it. In the lower part 32, a pressure is first generated, whereby the film section 43 is pressed against the heating plate 42 (step c). The pressure rise in the lower part 32 is monitored by means of the lower pressure gauge 40 (step d).

Further, in the process block II, the pressure supply in the lower part 32 is interrupted (step e) and heating of the heating plate 43 is started according to a heating time (step f) when the pressure in the lower part 32 has reached a set value (target process value). The film section 43 is now wrinkle-free on the underside of the heating plate 42 and can be heated quickly. The pressure level is maintained in the lower part 32 during the heating time.

At the end of process block II or at the beginning of process block III, i. after the heating time has elapsed, the lower vent valve 37 opens (step g). In addition, the upper pressure valve 28 opens (step h) and closes the upper vent valve 39 (step i). In process block III, the heated film section 43 is then formed. In this case, the film section 43 is pressed into the lower part 32 and formed into a packaging tray M.

In process block III, the pressure increase generated in the upper part 33 is monitored (step k). As the pressure in the lower part 32 drops (step j), the pressure in the upper part 33 increases up to a threshold (target process value) (step k). Upon reaching the threshold pressure in the upper part 33, the pressure generation in the upper part 33 is interrupted (step I) and a stabilization time (Cooling time) started (step m). During the stabilization time, the pressure level in the upper part 33 is maintained so that the generated packaging tray M retains its shape. At the end of the stabilization time, the molding process according to the process block III is completed. The packaging tray M is now cured.

At the beginning of process block IV, the upper vent valve 39 opens (step n). As a result, the pressure level in the upper part 33 drops. From a predetermined pressure threshold (desired process value) in the upper part 33, the lifting mechanism 35 opens the forming station 16 (step o). The molded packaging tray M can now be conveyed out of the mold chamber 34, at the same time a new, to be formed film section 43 moves into the forming station 16.

Depending on the type of film and / or tool type used, the threshold pressure values mentioned in the example described above, in process blocks II and III, can vary. The control unit 2 is preferably configured to automatically generate the respective threshold pressure values as desired process values from the memory 7, in particular by means of the database 10. Furthermore, the control unit may vary the heating and stabilization time (steps f and m) at least with regard to the film material and / or the tool type.

FIG. 5a shows the forming station 16 according to another embodiment variant. The process mode of the forming station 16 shown in FIG. 5a is shown in FIG. 5b.

The forming station 16 from FIG. 5a comprises a separate heating chamber 45, which is operated as a preheater. The heating chamber 45 is arranged in the process direction in front of the molding chamber 34. Within the heating chamber 45, a lower and an upper heating plate 46, 47 are provided. Between these, the film portion 43 to be heated is performed. Above the upper heating plate 47, a pressure generator 48, in particular an inflatable membrane is arranged, which presses the upper heating plate 47 against the lower heating plate 46 in the inflated state.

Further, the heating chamber 45 and the mold chamber 34 are each provided with lower and upper pressure and vent valves 36, 36 ', 37, 37', 38, 38 ', 39, 39'. The applied pressures are detected in the heating chamber 45 and the mold chamber 34 respectively by means of lower and upper pressure gauge 40, 40 ', 41, 41'. A pressure applied in the pressure generator 48 is determined by means of a pressure generator 49.

Figure 5a shows that the heating chamber 45 and the mold chamber 34 can be opened or closed simultaneously when the lower part 32 is adjusted by means of the lifting gear 35. It would also be conceivable to form the lower part 32 in two parts, wherein the respective parts of the Lower parts 32 are separated from each other by means of specially designed hoists 35 are adjustable.

FIG. 5b shows a process diagram for the molding station 16 depicted in FIG. 5a. In the dual-chamber design of the molding station 16, the heating and the molding take place parallel to one another in terms of time. The processes from process blocks II and III therefore do not run consecutively. For better understanding, however, the heating and the molding will be described separately below.

The process diagram 44 'shows, in a heating function block HB, working processes that take place in the heating chamber 45 and in a forming function block FB operating processes that take place in the forming chamber 34.

First, in the process block I, the forming station 16 is closed (step a '). The hoist 35 raises the lower part 32, whereby the heating chamber 45 and the mold chamber 34 close. The heating function block HB shows that the lower vent valve 37 is closed (step b '). In addition, the heating function block HB shows that a vacuum is generated in the heating chamber 45 in the lower part 32 by the lower pressure valve 36 to pull the film section 43 onto the lower heating plate 46 (step c '). Likewise, a pressure in the upper part 33 of the heating chamber 45 is applied, which is however optional. For this purpose, the upper pressure valve 38 opens (step d '). In addition, the pressure generator 48 presses on the upper heating plate 47, whereby the film portion 43 is firmly clamped between the lower and the upper heating plate 46, 47 (step e '). In particular, 45 proportional control valves can be used for precise pressure generation in the upper part 33 of the heating chamber.

The heating function block HB also shows that a pressure reaction within the heating chamber 45 is delayed in time relative to the switching processes at the pressure valves (step c 'and d') begins (dead time). This is taken into account in the control process of the molding station 16. On the basis of such dead time control, the valve switching processes (step c 'and d') can be triggered prematurely, for example 100 ms, already when the forming station 16 is not yet in the closed position (see step a '). This happens, for example, by means of a displacement measuring unit for the hoist 35, the Wegmesseinheit from a certain closing travel of the hoist 35 gives a signal to the control unit, so that it controls the corresponding valves early.

In the heating function block HB, the respective pressures in the heating chamber 45 are monitored at the beginning. As soon as a predetermined pressure level is detected in the lower part 32 by the pressure gauge 40 (step f), the control unit 2 initiates a heating process on the lower heating plate 46 (Step g '). The pressures in the upper part 33 can be regulated as desired during the heating process. In particular, the pressures in the top 33 are lowered from a predetermined pressure within the top 33 and / or within the pressure generator 48 to a predetermined pressure level (steps h 'and i').

It is further shown that the vacuum in the lower part 32 and the pressure in the upper part 33 increase almost simultaneously (step f and j '). The additionally applied pressure by means of the pressure generator 48 increases delayed (step k '), only after the pressure level in the upper part 33 and / or the vacuum level in the lower part 32 have each assumed a predetermined value.

In the form-function block FB, the lower and / or upper pressure valve 36 ', 38' as the lower and / or upper pressure valve 36, 38 of the heating chamber 45 early on in accordance with the dead time control early, for example, 100ms before the forming station 16 is closed, controlled (step Γ and m '). The pressure increase in the upper part 33 and / or the vacuum formation in the lower part 32 are monitored by the pressure gauges 40 ', 41'. The lower vent valve 37 'remains closed during the molding process (step n').

From a predetermined pressure in the upper part 33 and / or vacuum in the lower part 32, the stabilization time starts to run (step o '). This can in particular also be set in motion during the pressure and / or vacuum build-up (step p '). During the stabilization time, the molded packaging tray cools M, thereby becoming dimensionally stable.

Figure 5b shows that the heating time in the heating chamber 45 is shorter than the stabilization time in the mold chamber 34. Nevertheless, the mold chamber 34 is vented earlier than the heating chamber 45 (steps q 'and r'). While the mold chamber 34 immediately initiates aeration at the end of the stabilization time (step q '), the respective valves 36, 37, 38, 39 of the heating chamber 45 are not vented until the pressure and / or the vacuum in the mold chamber 34 has been reduced ( Step s'). With a certain time delay, the pressures in the heating chamber 45 are then reduced (step t ').

As soon as the pressure level in the mold chamber 34 and in the heating chamber 45 has reached and / or fallen below a predetermined value together, the hoist 35 moves down and opens the forming station 16 (step u '). According to FIG. 5b, the forming station 34 could already have been opened at an earlier time (step s'). Therefore, it would also be conceivable to use separately functioning hoists 35 on the heating chamber 45 and on the mold chamber 34. This would reduce waiting times (step v '). Alternatively, the control unit 2 could coordinate the ventilation of the respective valves on the heating chamber 45 and on the molding chamber 34 in such a time that within the Heizkam- mer 45 and the mold chamber 34 at the same time at the same time a predetermined pressure level for opening the mold station 16 sets. In the case of FIG. 5b, for example, the venting of the heating chamber 45 (step r ') could be initiated earlier in order to bring the pressure reduction (steps t' and s') closer together in terms of time.

Figure 6a shows the sealing station 17 of Figure 2 in an enlarged view. The process-controlled functional principle according to the invention can also be applied to this sealing station 17.

In a further variant, not shown, a shaping punch for the molding chamber 34 is provided. According to the prior art, the punch movement was started down and started time-controlled with some delay of the molding process. In the variant according to the invention, the punch movement is started and the molding process is also started as soon as the forming punch has reached a predetermined position.

In FIG. 6a, the sealing station 17 comprises a sealed lower part 49 and a sealing upper part 50. The sealed lower part 49 is height-adjustable by means of a lifting mechanism 51. Between the lower sealing part 49 and the sealing upper part 50, a sealing chamber 52 is formed. In the sealing chamber, the lidding film 24 is sealed onto the packaging tray M to contain therein a (food) product. Above the cover foil 24, a sealing plate 53 is positioned. Furthermore, a pressure generator 48, for example an inflatable membrane, is provided within the sealing top 50, which can be used to depress the sealing plate 53 in order to seal the lidding film 24 on the packaging tray M.

The sealing lower part 49 comprises a lower valve unit 54 for generating a vacuum and for venting the sealing lower part 49. The sealing upper part 50 comprises an upper valve unit 55 for generating a vacuum and ventilating the sealing upper part 50.

The sealing top 50 is equipped with an upper pressure gauge 56. The pressure in the upper pressure generator 48 is measured by means of a pressure generator 57. The sealed lower part 49 is equipped with a lower pressure gauge 58. In addition, a vacuum generator 59 is formed in the seal bottom 49, which can generate a vacuum in the packaging tray M. The vacuum generated in the packaging tray M is measured by a vacuum gauge 60. For filling the packaging tray M with any atmospheric gas, a gasification unit 61 may be provided in the seal base 49.

FIG. 6b shows the functional relationships at the sealing station 17 from FIG. 6a. In this case, the sealing process 44 "takes place in a process-controlled manner according to the invention. First, in the process block I of FIG. 6b, the sealed lower part 49 is moved from one open to one closed position by means of the lifting mechanism 51, in which the sealed lower part 49 with the sealing upper part 50 locks the packaging tray M and the cover film 24 positioned above it within the sealing chamber 52 (step a ").

Before the seal base 49 arrives in the closed position, the lower valve unit 54 is actuated to evacuate the seal base 49 (step b "). With little delay, however, before reaching a closed position of the seal base 49, the upper valve unit 55 is evacuated Seal top 50 is driven (step c "). The time advance for driving the valve units 54, 55 serves to eliminate dead times that accumulate from activation to the valve reaction and further to the actual pressure or vacuum build-up. These dead times can be determined by the control unit 2 in a test run.

In process block I, the valve units 54, 55 for ventilation remain closed (step d ") in order to build up a vacuum both in the lower sealing part 49 and in the upper sealing part 50. With a certain time delay, at the beginning of the process block II in the lower sealing part 49 and in the upper sealing part 50 The packaging depression M is first fixed by the generated vacuum in the sealing lower part 49. The vacuum in the sealing upper part 50 ensures that the cover film 24 is aligned without folds over the packaging depression M.

In addition, the vacuum pressure profiles are monitored within the lower sealing part 49 and the sealing upper part 50. In process block II, a vacuum is generated in the lower sealing part 49 and / or in the sealing upper part 50 until a predetermined vacuum value in the sealing lower part 49 and / or in the sealing upper part 50 is detected (step e ").

In a further variant, a moisture sensor, not shown, is provided to detect the degree of moisture in vacuum for the product. It may happen that a given final vacuum can not be achieved because the product generates too much moisture. In this case, this recognizes the control and terminates this process step, although the final vacuum, namely the predetermined vacuum value, has not yet been reached.

According to FIG. 6b, a predetermined vacuum pressure in the sealing upper part 50 is reached at the end in the process block II, which starts to inflate the pressure generator 48, as a result of which the sealing plate 53 is pressed downwards and presses the cover film 24 onto the edge of the packaging trough M. In the process, a contact pressure builds up in the sealing area (step f ") .This mechanical contact pressure can be measured by means of at least one force sensor 62 (see FIG. 6a) provided in the lower sealing part 49 and / or in the associated lifting mechanism 51 become. Alternatively, the pressure of a membrane can be determined by means of a pressure sensor, which generates the sealing force.

A short time later, when the contact pressure is equal to a maximum sealing pressure (step h "), a sealing time is set in motion (step i") during which the lidding film 24 is welded to the packaging tray M. The sealing time may be determined depending on the packaging materials used and / or the type of sealing tool used.

During the sealing time, with a time delay for venting the lower sealing part 49, the sealing upper part is also ventilated (step j ") .The triggering event for this can be, in particular, the return of the vacuum in the lower sealing part 49 to a specific vacuum value (step k").

Until the end of the sealing time in process block III, the sealing plate 53 remains depressed. Once the sealing time has elapsed, the sealing plate 53 is raised (step I "), for which purpose the pressure is released from the pressure generator 48 and monitored (step m"), whereby the sealing plate 53 can be moved back to a starting position. As soon as the pressure in the pressure generator 48 reaches a predetermined value, the sealing station 17 can be opened in process block IV (step n "). The opening of the sealing station 17 can already be initiated when the sealing plate 53 has not quite reached its initial position, ie the pressure in the pressure generator 48 has not yet completely dissipated.The vacuum in the sealing lower part 49 and in the sealing upper part 50 is already completely degraded by the venting at this point in time.

The invention turns away from a time-based control of the manufacturing process on a packaging machine. Timed programs are no longer considered according to the invention in the manufacturing process. Rather, the packaging machine according to the invention intervenes by means of the control unit 2 self-controlling based on current detected process parameters in the manufacturing process to coordinate the respective performed on the work units 3 program flows P themselves and / or in coordination with each other self-controlling. This leads to an economical production process, wherein the packaging machine 1 according to the invention is particularly suitable for producing a large number of different products due to its high availability.

As a further embodiment, it is conceivable that information and / or specifications of consumables, such as the film web 22 and the cover film 24, for example, automatically detected by RFID and processed by the controller. In this case, RFID reading units 70, 70 'can read out an RFID tag mounted on the film roll. Forming or sealing tools can preferably be detected by wire or wirelessly by means of RFID, identified and / or the information contained on it read and transmitted to the controller.

Claims

claims

1 . Packaging machine (1) comprising a control unit (2), a plurality of measuring devices (5) and a plurality of working units (3) for different processes, wherein the control unit (2) with the working units (3) and with the measuring means (5) is functionally connected in that the measuring devices (5) are configured to acquire actual process values (I) at the respective working units (3) and forward them to the control unit (2) in order to monitor a process status at the respective working units (3) Control unit (2) is designed to perform a program sequence by comparing (V) the actual process values (I) forwarded to them by the respective measuring devices (5) with associated desired process values (S) from a memory (7) connected to them (P) for the respective working units (3) themselves and / or with respect to the working units (3) adapted to produce self-controlling, in accordance with which the respective working units (3 ) function in accordance with the actual process values (I) detected thereon themselves and / or coordinated with one another.

2. Packaging machine according to claim 1, characterized in that the packaging machine (1) is a thermoforming packaging machine (15), a Traysealer (28) or a chamber belt machine (29).

3. Packaging machine according to one of the preceding claims, characterized in that the memory (7) contains a database (10) which is configured with regard to format-dependent, process-dependent and / or film-dependent data of a product to be produced by the packaging machine (1) and / or or derive the target process values (S) with regard to specific tool parameters.

4. Packaging machine according to claim 3, characterized in that the packaging machine (1) comprises an RFI D reader (70, 70 ') which is configured to read information from a, attached primarily to a packaging film, RFID tag and in the database (10) to deposit.

5. Packaging machine according to claim 3 or 4, characterized in that the database (10) is formed as part of a database system (9), wherein the database system (9) further comprises a database management unit (1 1), which for a NEN bidirectional data exchange between the control unit (2) and the database (10) is configured.

6. Packaging machine according to one of the preceding claims, characterized in that the desired process values (S) are based on data of the product to be produced, which for this one sealing surface, a sealing pressure, a volume to be evacuated, a type of film and / or a film thickness.

7. Packaging machine according to one of the preceding claims, characterized in that the desired process values (S) an optimum molding and / or sealing temperature, an optimal heating, sealing and / or molding pressure, and / or for a trained as a molding station working unit (3) indicate at least one stabilization time.

8. Packaging machine according to one of the preceding claims, characterized in that the memory (7) in the control unit (2) is integrated or is present as an external unit.

9. Packaging machine according to one of the preceding claims, characterized in that the memory (7) with an external network (13) is connectable, wherein the memory (7) via the external network (13) is updatable and / or controllable.

10. Packaging machine according to one of the preceding claims, characterized in that the respective measuring means (5) comprise at least one force, pressure, displacement, temperature, infrared, ultrasonic, induction, laser and / or moisture sensor.

1 1. Packaging machine according to one of the preceding claims, characterized in that the working unit (3) comprises a movable lower part (32, 49) and an upper part (33, 50), the between a forming chamber (34) or a sealing chamber (52) include and each have at least one pressure measuring unit (40, 40 ', 41, 41', 49).

12. Packaging machine according to one of the preceding claims, characterized in that one of the working units (3) is designed as a forming station (16) comprising at least one heating plate (42).

13. Packaging machine according to claim 12, characterized in that the forming station (16) comprises a heating chamber (45) and a forming chamber (34), which are spatially separated from each other.

14. Packaging machine according to one of the preceding claims, characterized in that one of the working units (3) is designed as a sealing station (17).

15. Packaging machine according to one of the preceding claims, characterized in that the actual process value (I) is in the working unit (3) detected pressure, wherein the control unit (2) is configured to at least one working process on or at least one other work unit (3) to start or start when the detected pressure has reached a predetermined pressure level.

16. Packaging machine according to claim 15, characterized in that the working process is a heating or cooling process, which takes place in accordance with a heating or cooling time present from the memory (7).

17. Method for self-control of a program sequence (P) of a process at different working units (3) of a packaging machine (1), wherein according to the program sequence (P) a process and / or according to the program sequence (P) several, functionally coordinated processes during the Operation of the packaging machine (1) at the respective working units (3) are performed, wherein at the respective working units (3) actual process values (I) are detected and forwarded to a control unit (2) of the packaging machine (1), wherein the control unit ( 2) compares the actual process values (I) passed to them with the associated desired process values (S) and, as a result, autonomously controls the respective program sequence (P) for the work units (3) themselves and / or with respect to the respective work units (3) and based on the operation of the packaging machine (1) coordinated.