EP3392172A1 - Method for monitoring an unwinding process, unwinding device and unwind system - Google Patents

Abstract

The invention relates to a monitoring method (100) for monitoring an unwinding process of an unwinding device (2), comprising the following steps: At least partially unwinding (101) a web material (11) from a roll (10), - Detecting (102) at least one irregularity (12) of the web material (11) and / or the unwinding process. Furthermore, the invention relates to an unwinding device (2) for carrying out an unwinding process and to an unwinding system (5) for carrying out a unwinding process.

Description

The present invention relates to a monitoring method for monitoring an unwinding process, an unwinding device for carrying out a unwinding process of a web material and an unwinding system.

In order to bring an endless material, such as a manufactured film, into the distribution or to the place of use, these are often provided in portions in the form of coils. Such reels are first wound on a take-up device to be unwound at the site corresponding to a unwinding device. After unwinding often follow other processing, such. B. the creation of plastic bags, the wrapping of stacked packaged goods for securing cargo or the like. When unwinding the winding, however, errors may occur which have their cause in the manufacturing process of the winding, ie in the production of the film and / or in the winding or which have their cause in a faulty settlement. Therefore, it is desirable to detect such errors and to be able to draw a conclusion on the cause of the error at best.

From the prior art, it is also known to store relevant data of an unwinding process with a time stamp in order to draw conclusions about the course of a production. The disadvantage here, however, is that the time alone alone often gives inaccurate conclusions, since the exact winding parameters are unknown. Thus, such reels are often provided with a weight indication, but without allowing an accurate conclusion as to which thickness of the film material is actually provided for the reels. Due to a varying thickness of the film material, a calculation of the film diameter may also have inaccuracies. Furthermore, air inclusions in the winding can cause further inaccuracies, so that a reliable conclusion on the position to the relevant data in the winding is not possible.

It is an object of the present invention to at least partially overcome the foregoing disadvantages known from the prior art. In particular, it is an object of the present invention to improve an inference from an unwinding process to a manufacturing process of a reel in terms of reliability and / or accuracy.

The above object is achieved by a monitoring method having the features of claim 1 and an unwinding device having the features of claim 12 and an unwinding system having the features of claim 17.

Further features and details of the invention will become apparent from the dependent claims, the description and the drawings. In this case, features and details that have been described in connection with the monitoring method according to the invention, of course, also in connection with the inventive Unwinding device and / or the unwinding system according to the invention and in each case vice versa, so that with respect to the disclosure of the individual invention aspects always reciprocal reference is or may be.

• Zumindest teilweises Abwickeln eines Bahnmaterials von einem Wickel,
• Erfassen zumindest einer Unregelmäßigkeit des Bahnmaterials und/oder des Abwickelprozesses,
• Bestimmen einer Korrelation der Unregelmäßigkeit zu zumindest einem Laufparameter des Wickels.

According to the invention, the monitoring method for monitoring an unwinding process of an unwinding device comprises at least the following steps:

• At least partially unwinding a web material from a reel,
• Detecting at least one irregularity of the web material and / or the unwinding process,
• Determining a correlation of the irregularity to at least one run parameter of the roll.

• Erfolgloses Öffnen eines Schlauches des Bahnmaterials,
• Aufbrechen eines aus dem Bahnmaterial hergestellten Produktes,
• Reißen des Bahnmaterials,
• Fehlen zumindest eines Teils eines Druckbildes auf dem Bahnmaterial,
• Erhöhter Schlupf an einem Antriebsmittel beim Abwickeln des Bahnmaterials,
• Veränderte Drehmomente und/oder Kräfte während der Verarbeitung des Bahnmaterials.

The winding may preferably be mounted on a winding support during unwinding. In this case, the winding has in particular a winding tube and at least a part of the web material. During unwinding, the web material is thereby reduced on the reel and preferably fed to a further processing station. Preferably, the web material may comprise a plastic film. Thus, plastic films have a complex production process in which, if necessary, many parameters have to be taken into account so that an exchange of information between individual processes in the case of plastic films is particularly advantageous. Additionally or alternatively, however, further materials of the web material are conceivable. The detection of the at least one irregularity of the web material and / or the unwinding process can be carried out in particular by means of sensors or calculations. Thus, for example, a detection unit may be provided by which an irregularity is detected. Preferably, the irregularity can be detected optically and / or acoustically. For example, the detection unit can be designed to detect the irregularity by means of ultrasound and / or can have a camera. Furthermore, it is conceivable that the irregularity is detected electronically and / or mathematically, for example by measuring a required current of a drive means or the like in order to conclude on a drive power. An irregularity may, in particular, be understood as a critical or uncritical feature in the processing process during unwinding. Thus, the irregularity may preferably be an error include, which has the web material. For example, the irregularity may include at least one of the following features:

• Unsuccessful opening of a hose of the web material,
• Breaking up a product made from the web material,
• Tearing the web material,
• Lack of at least part of a printed image on the web material,
• Increased slip on a drive means during unwinding of the web material,
• Modified torques and / or forces during processing of the web material.

Thus, the irregularity may directly or indirectly affect the web material and / or the unwinding process. For example, it can be provided that the web material is wound up as a tube, which is opened during unwinding or after unwinding, so that a three-dimensional shape is created from a hose that has been previously folded together. Furthermore, it can also be stated that the web material, for example, does not withstand the processing of the web material to bag this processing and tears open a corresponding bag. Such tearing can also take place during unwinding or shortly after unwinding, so that this may represent a possible irregularity. Furthermore, the web material may have a printed image. For example, for the production of plastic bags, the web material may first be printed before it is wound up. If a part of this printed image, e.g. due to lack of color in a printer unit, this can be detected as an unevenness in unwinding. Furthermore, an altered slip during unwinding of the web material can be understood to mean that a drive means, which ensures propulsion of the web material, at least partially slips. The speed of the drive and the speed of the web material differ accordingly. Furthermore, forces and / or moments can be measured at different points during the unwinding process, which can be an indicator of the occurrence of an irregularity.

The running parameter may preferably also be referred to as a running meter. Thus, the running parameter, in particular the actual developed length of the web material of the winding up to the occurrence of irregularity. In this case, the length can be related to the irregularity in different ways, ie correlated. Thus, the running parameter may include a length ranging from the starting point of the web material, ie, for example, from the first unwound end of the web material, to the beginning of the irregularity, to the end of the irregularity, or to an average value between the beginning and end of the irregularity. In particular, the correlation of the irregularity to the running parameter can thus be understood to mean an assignment of a specific value of the running parameter to a position of the irregularity relative to the winding and / or vice versa. In particular, the running parameter for the irregularity is correlated or correlated accordingly. For example, if the irregularity includes the absence of a printed image, the running parameter may include the length from the beginning of the unwinding of the web material to the beginning of the absence of the printed image and / or until the end of the absence of the printed image. Further, the running parameter may include the length of the unwound material until the irregularity occurs in the form of a particular event, eg, a change in forces and / or moments. Thus, the correlation between the irregularity and the running parameter may be understood to relate the irregularity, particularly occurrence of the irregularity, to the running parameter. This can be carried out, for example, by providing a table having at least two columns, the irregularity being written into the first column and the running parameter or a value of the running parameter being traced back to the second column of the table, at which position in the wrap the irregularity has occurred. In particular, a field variable of a computer program may be provided instead of the table or provide the table. In particular, this makes it clear that the irregularity is assigned to a value of the running parameter, that is to say occurs at a position of the running parameter. An accumulation of irregularity in a certain range of the running parameter can thus be determined.

• Bewerten der Korrelation zwischen der Unregelmäßigkeit und dem Laufparameter.

By the monitoring method according to the invention, it is thus possible to close the position of the irregularity in the winding. As a result, conclusions can be drawn on errors during the manufacture of the package and / or during unwinding of the package. For example, there may be an increased occurrence of an irregularity in the core of the roll let it be concluded that this was wound up during winding with a too high winding hardness. Thereby, the manufacturing process of the coil can be improved. Furthermore, an estimation can be made as to whether the irregularity has occurred due to an error in the settlement process. This may be relevant for warranty issues, for example, if the question arises as to whether the roll has exhibited a defect when it has been delivered to a customer or if the defect has arisen due to faulty handling of the roll. By means of the monitoring method according to the invention, a further indicator in the question of proof can be provided here. Thus, the monitoring process may further include the following steps:

• Evaluate the correlation between the irregularity and the run parameter.

The evaluation can also be carried out automatically, for example, on the basis of predetermined criteria, in particular by means of a computing unit. As a result, it is thus also possible for a corresponding inference to a cause of the irregularity to be carried out automatically in the context of the method, and the conclusion thus to have a reproducible accuracy. In particular, by the use of the running parameter of the winding, the running parameter is related to the same winding, so that the conclusions can be attributable to a specific winding, also based on its manufacture.

In the context of the invention, it is also conceivable that the running parameter is determined during the unwinding of the web material from the winding. Preferably, the running parameter can be determined continuously during the unwinding of the web material from the winding. The determination of the running parameter may include a direct measurement of the running parameter. The running parameter can thus be recorded and recorded continuously during unwinding, for example, so that a value corresponding to the irregularity is immediately available when the irregularity is detected. Alternatively, the run parameter can not be determined continuously during the unwinding process by, for. B. the running parameter is measured only when an irregularity is detected. A continuous acquisition of the running parameter can include an analog and / or a digital measurement of the running parameter. Thus, a detection means for detecting the running parameter can work incrementally and z. B. after output a signal over a certain length or revolution, which can be used to deduce the run parameter. By detecting the run parameter during unwinding it is z. B. not necessary to measure this manually, so that the monitoring process can be further automated and thus costs can be saved while a reproducible, high accuracy can be provided.

The running parameter can preferably be determined by detecting a preferred parameter on the web material. Preferably, a measurement of a number of revolutions of the coil can additionally be carried out. The preference may be given to a part of a drive means which acts on the web material in order to allow it to drive forward. A preferred parameter may include a speed, in particular a rotational speed and / or a tangential speed of a drive roller, with preference. The measurement of the preferred parameter can be set directly in relation to the actually processed length and thus a high-quality indicator for the running parameter. In preference, the web material already runs in a flat extension, so that according to changing diameters of the roll on preference no or play only a minor role. However, particularly preferably, the running parameter can be determined by measuring the preferred parameter and by measuring the number of revolutions of the winding. The measurement of the number of revolutions of the reel permits a correction of the preferred parameter, wherein here, preferably, an estimate of the diameter of the reel can be given. Thus, the actual measurement of the running parameter can take place on preference, but these can be corrected on the basis of the measurement of the number of revolutions of the reel in order to at least partially eliminate slip on the merit. This results in a high accuracy of the determination of the running parameter, so that in particular a conclusion on the cause of the irregularity can be improved in its accuracy.

• Eintragen der Korrelation der Unregelmäßigkeit zu dem Laufparameter in eine Datenbank

It is further conceivable in a monitoring method according to the invention that the monitoring method further comprises the following step:

• Enter the correlation of the irregularity to the run parameter in a database

A database can preferably be understood as an electronic table. Thus, for example, a SQL server can be maintained on a storage medium, which provides a corresponding database. In particular, the correlation of the irregularity with the running parameter can be determined by relating the irregularity and the running parameter in such a way that they can be assigned to one another when they are entered into the database. In addition, for example, after the unwinding process or at another time, the database can be viewed and the correlation between irregularity and run parameters can be tracked. For example, several irregularities can be evaluated together after the expiry of an unwinding process, or several irregularities from several different unwinding processes can be evaluated together. For example, a conclusion can only emerge from the fact that several batches of a batch are examined together for irregularities over the database, so that a pattern emerges only when examining the several bobbins. Thus, by entering the irregularity and the running parameter into a database, an improvement in the possibility of drawing conclusions from the data obtained on the related processing or manufacturing processes.

It is also conceivable in a monitoring method according to the invention that the irregularity when entering the correlation into the database is brought into a further correlation at a time specification. Thus, for example, a first correlation with the run parameter can be determined and a second correlation with time can be generated or determined. The time indication may include a time, in particular a time, of the time of occurrence of the irregularity. For example, the time indication may be provided as a third column in a table of the database. By detecting the time or the time of occurrence of the irregularity can also be further improved the conclusions that can be drawn from it. Thus, it can be estimated, for example, whether irregularities occur more frequently in the working layer of a particular operator than in another working layer, so that incorrect operations during the unwinding process can be identified. Furthermore, the time indication can draw conclusions about a connection between the occurrence of the irregularity and another event during the unwinding process, such as, for example, a power failure, allow. As a result, there are several relationships between the irregularity, the time and the running parameter, so that further information about the handling of a specific roll during the processing process converge. In particular, a lateral position of the irregularity can also be determined in correlation with the running parameter in order to be able to obtain further information for a conclusion on a cause of the irregularity in this respect as well.

In the context of the invention, the database may advantageously be provided on a server and / or an internal storage unit of the unwinding device. In this case, an external server can be understood to mean an arithmetic unit which has a storage capacity for the database and is provided outside the unwinding device. So the external server z. B. be part of a palletizing system or are located externally at a service company. Thus, the storage of the data may be outsourced to z. B. the capacity of a provider of computing power and / or storage to use, so that costs of the unwinding device can be saved. This can, for. B. only have a communication interface, so that the unwinding device can communicate with the database on the external server. Furthermore, the external server can also be connected, for example, to a take-up device or be part of a take-up device, so that data about the windings to be processed flows back directly to the production process of the take-up rolls. Additionally or alternatively, it can be provided that the database is provided on an internal storage unit and / or a mobile storage unit. Thus, for example, the unwinding device itself comprise a corresponding memory unit, the z. B. is built as an internal HDD or SSD hard drive in the unwinding device and thus the data generated are available directly to the unwinding device. A mobile storage unit has the advantage that it can be connected to the unwinding device, for example, via a USB interface, while the data is being transmitted and can then be transported as desired in order to store the data, for example. B. a development department to provide.

• Visuelles und/oder akustisches Ausgeben einer Warnmeldung, wenn die Unregelmäßigkeit erfasst wird oder die Unregelmäßigkeit von einer vordefinierten Unregelmäßigkeitsart ist.

In the context of the invention, it is also conceivable that the monitoring method further comprises the following step:

• Visually and / or acoustically issuing a warning message when the irregularity is detected or the irregularity is of a predefined type of irregularity.

By the warning message, for example, an operator of the unwinding device can be informed about the occurrence of the irregularity, so that it can initiate corresponding countermeasures or reaction measures. The warning message z. B. be issued via a warning light, or display a warning message. Additionally or alternatively, it is conceivable that an acoustic signal will be output, such as a warning sound via a loudspeaker. Under a predefined type of irregularity can be understood that z. For example, a particular type of defect in the web material is particularly critical and accordingly requires the warning message, while other types of defects of the web material are merely recorded and correlated with the run parameter accordingly. For example, a changed slip may be uncritical and therefore require no warning messages, but a lack of print image may require that appropriately crafted follow-on products be discarded or the unwinding process interrupted.

• Visualisieren der Korrelation der Unregelmäßigkeit zu dem Laufparameter.

Furthermore, in a monitoring method according to the invention, it can be provided that the monitoring method comprises the following step:

• Visualizing the correlation of the irregularity to the run parameter.

The visualization can be done for example on a display, wherein z. For example, a chart may be displayed that indicates the occurrence of irregularities over running parameters. As a result, an operator of the unwinding device can be shown, for example, an accumulation of the irregularity in a specific running parameter range, so that the latter can already draw conclusions from the existing correlation at the unwinding device. Thus, the display may preferably be arranged on the unwinding device. Additionally or alternatively, it can be provided that the visualization of the correlation between the irregularity and the run parameter is performed on a display outside the unwinding device. For example, it may be provided that the unwinding device is in communication with a network, so that the data can be transmitted to a monitoring station and / or directly to a development department in order to send an evaluation directly to an evaluating point. Thus, visualization can simplify the monitoring process and increase comfort, in particular for the persons involved, so that ultimately time can be saved in the evaluation.

• Ermitteln einer Wahrscheinlichkeit für eine Ursache der Unregelmäßigkeit in einem Herstellprozess des Bahnmaterials und/oder in dem Abwickelprozesses.

Furthermore, in a monitoring method according to the invention, it is conceivable that the monitoring method further comprises the following step:

• Determining a likelihood of a cause of the irregularity in a manufacturing process of the web material and / or in the unwinding process.

Thus, for example, a probabilistic determination can already be carried out automatically from an accumulation of irregularities in the region of a certain running parameter or from the correlation of a single irregularity with the running parameter. As a result, it may not be necessary to perform a rating manually. In this case, the probability can be determined by a computing unit of the unwinding device and therefore a reproducible result can be output. Furthermore, the monitoring method can thereby be further automated, whereby a uniform basis can be created in order to determine the relationship or the probability.

In the context of the invention, it may further be provided that the irregularity comprises a process parameter which lies outside of a parameter range. For example, the parameter range can have at least one parameter limit, at which the irregularity is defined above. If the process parameter therefore exceeds or falls below this parameter limit, an irregularity is assumed. So the parameter limit can be an absolute or a relative limit. Preferably, two parameter boundaries are provided which define a closed parameter range down and up. Exemplary parameter limits can be opacity a print image, the transparency of a film material or a tolerable slip on preference. As already described, these parameter limits can be designed absolutely, ie predefined or predefined at the beginning of the monitoring process. Additionally or alternatively, relative parameter limits may be provided which, for example, define an anomaly such that the process parameter z. B. is wrapped over a certain length dynamically during the unwinding process and a certain percentage is considered above and / or below as an irregularity.

In a monitoring method according to the invention, it is also conceivable that a number of products produced from the web material is determined on the basis of the running parameter. Preferably, the products may be bags made of plastic film. Thus, it is possible by the running parameter and in particular by taking into account any unprocessed irregularities of the web material to perform a calculation of the total length and / or total area of the web material. As a result, in turn, the number of products produced from the web material can be calculated from a specific winding. Compared to an estimate of the weight of the roll, there is also the advantage that the determination based on the running parameter is substantially or completely adjusted by a possibly fluctuating thickness of the web material.

The sequence of the individual method steps of a monitoring method according to the invention can be carried out in the order described. Furthermore, however, another, than the particular order of the method steps described is conceivable. In particular, individual method steps or all method steps can be repeated and / or executed in parallel.

• Zumindest teilweises Abwickeln des Bahnmaterials von einem Wickel,
• Erfassen zumindest eines Laufparameters des Wickels,
• Berechnen der Anzahl von aus dem Bahnmaterial produzierten Produkten, insbesondere Säcken, auf Basis des Laufparameters des Wickels, insbesondere wobei zumindest eine Unregelmäßigkeit des Bahnmaterials und/oder des Abwickelprozesses berücksichtigt wird.

Somit könnte in dem Quantifizierungsverfahren ein weiterer Aspekt der vorliegenden Erfindung liegen. Dadurch ergibt sich der Vorteil, dass die Bestimmung auf Basis des Laufparameters im Wesentlichen oder vollständig um eine ggf. schwankende Dicke des Bahnmaterials bereinigt sein kann. Insbesondere gelten Merkmale und Details, die im Zusammenhang mit dem erfindungsgemäßen Überwachungsverfahren und/oder der erfindungsgemäßen Abwickelvorrichtung und/oder dem erfindungsgemäßen Abwickelsystem beschrieben worden sind, selbstverständlich auch im Zusammenhang mit dem erfindungsgemäßen Quantifizierungsverfahren und jeweils umgekehrt, sodass bezüglich der Offenbarung zu den einzelnen Erfindungsaspekten stets wechselseitig Bezug genommen wird bzw. werden kann. Insbesondere können die Merkmale des jeweils kennzeichnenden Teils der vorliegenden Unteransprüche des erfindungsgemäßen Überwachungsverfahrens auch Weiterbildungen des Quantifizierverfahrens darstellen.In particular, the object is further achieved by a quantification method for determining a number of products produced from a web material in an unwinding process of an unwinding device, comprising the following steps:

• At least partially unwinding the web material from a reel,
• Detecting at least one running parameter of the roll,
• Calculating the number of products produced from the web material, in particular sacks, on the basis of the running parameter of the roll, in particular taking into account at least one irregularity of the web material and / or the unwinding process.

Thus, in the quantification process, another aspect of the present invention could be. This results in the advantage that the determination based on the running parameter can be substantially or completely adjusted by a possibly fluctuating thickness of the web material. In particular, features and details that have been described in connection with the monitoring method according to the invention and / or the unwinding device according to the invention and / or the unwinding system according to the invention, of course, also in connection with the quantification method according to the invention and in each case vice versa, so always with respect to the disclosure of the individual invention aspects mutual reference is or can be made. In particular, the features of the respective characterizing part of the present subclaims of the monitoring method according to the invention can also represent developments of the quantification method.

According to a further aspect of the invention, an unwinding device for carrying out a unwinding process of a web material is claimed by a reel. Preferably, the unwinding process can be monitored by a monitoring method according to the invention. The unwinding device has a winding holder on which the reel can be stored during the unwinding process. Furthermore, the unwinding device has a drive means, by means of which a propulsion of the web material can be generated, and a detection unit, by means of which at least one irregularity of the web material and / or the unwinding process can be detected. The detection unit is in communication with a computing unit, wherein a correlation of the irregularity to at least one run parameter of the winding can be determined by the computing unit.

The detection unit can be designed for optical and / or acoustic detection of the irregularity. For example, the detection unit may comprise a camera and / or an ultrasound sensor. Furthermore, the detection unit can have means for measuring force and / or torques. Depending on which Type of irregularity, the detection unit can be arranged on the drive means, on the winding support and / or on a frame of the unwinding device. Depending on the application, however, other arrangements are conceivable. Furthermore, the computing unit may be part of a computer or a controller. For example, a control unit of the unwinding device may comprise the arithmetic unit. The drive means may preferably comprise two driven rollers which are in contact with the web material so that the web material undergoes propulsion when the drive means are driven. In this case, the drive means may have a particular textured surface through which the preference of the web material is realized by friction. The winding holder may preferably comprise a winding mandrel on which the winding is pushed to carry out the unwinding, so that it is rotatably mounted on the unwinding device. Preferably, the detection unit and / or at least one measuring means for detecting the running parameter can be arranged on the winding holder.

Thus, an unwinding device according to the invention brings about the same advantages as have already been described in detail with reference to an inventive monitoring method. Thus, the irregularity can be detected by the detection unit and a correlation can be established by the arithmetic unit, in particular by which a conclusion on an occurrence of the irregularity is improved by the connection with the running parameter. The running parameter can preferably be detected by a measuring device and / or the detection unit and / or the arithmetic unit. In this case, the correlation can be established by the arithmetic unit, for example, by the fact that the arithmetic unit assigns the irregularity to the run parameter, for. For example, by a measured value is isolated and written according to the other measured value assignable in a table. Preferably, the computer unit can execute a computer program which establishes the correlation. Furthermore, the unwinding device, in particular the processing unit of the unwinding device, can be designed to carry out a quantification method for determining a number of products produced from the web material.

In the case of an unwinding device according to the invention, it is also conceivable, in particular, for the unwinding device to be designed for the production of sacks from the sheet material, in particular from tubular and / or flat sheet material. This can be the Unwinding at least one folding means for folding the bags and / or at least one closure means for closing the bags. Thus, the closure means may be configured to form a fold and / or to weld the web material to close the bags. The folding means may comprise a guide means by which the sheet material is in particular during driving so conductive that a bag shape is formed at least partially from the sheet material. Furthermore, the unwinding device can have at least one filling means, by means of which sacks produced from the web material can be filled. Thus, the unwinding device may be suitable for producing sacks ready for delivery from the web material and / or filling products, in particular so that the entire manufacturing process of the sacks can be reproduced by the unwinding device from the delivery of the raw material (eg web material and filling products). By detecting one or more irregularities, rejects can be reduced at the same time and / or delivery of defective bags can be avoided. The unwinding device thus preferably comprises a so-called FFS machine, the abbreviation FFS meaning "shape, fill and seal".

In the context of the invention, it is also conceivable that the arithmetic unit is in communication communication with a measuring unit for detecting a preferred parameter on the web material. In particular, the measuring unit may additionally be designed to measure a number of revolutions of the reel. In this case, the measuring unit may be part of the detection unit or form an independent structural unit within the unwinding device. For example, a measuring means for measuring the number of revolutions of a drive means can be provided. The number of revolutions may in particular comprise one revolution angle. Furthermore, the drive means may comprise at least one drive roller which by rotation drives the web material by friction and has a fixed diameter. About the number of revolutions and the diameter can then be determined by the measuring unit and / or the arithmetic unit, the actual propulsion of the web material. This can preferably be corrected by measuring a number of revolutions in order to achieve increased accuracy. This can be given a simple way to determine the actual propulsion of the web material and thus the running parameters, wherein a diameter of the roll plays no or only a minor role.

Preferably, a calculation of the running parameter can be carried out by the arithmetic unit. For example, the calculation may be performed based on a measurement of a merit of the web material and, in particular, a measurement of a revolution number of the reel. For example, the number of revolutions of the reel can serve to take into account a slip on preference in the calculation, and thus improve the accuracy of the calculation result or the measurement result with preference.

In an unwinding device according to the invention, the arithmetic unit can advantageously have a communication interface for data communication with a database, so that the correlation of the irregularity to the run parameter can be entered into the database via the communication interface. The communication interface may include a network connection or the like for wired transmission from the arithmetic unit to the database. Additionally or alternatively, the communication interface may enable wireless communication and include, for example, a WLAN unit. The database can continue to be provided on a storage medium, which z. B. may be part of the unwinding device. As a result, the arithmetic unit can be in communication with the memory unit, for example, directly via an internal wired connection. Thus, the memory unit may have a computer program for carrying out a monitoring method and / or for establishing the correlation between the running parameter and the irregularity. Thus, the database may be provided in particular on an external server and / or on an internal storage unit of the winding device. Additionally or alternatively, the database may be provided on a mobile storage unit. For example, the communication interface may be a USB interface through which z. B. an external hard drive can be brought into connection with the arithmetic unit, so that the database is portable. The database allows a number of irregularities and run parameters to be correlated and retrieved at a later time to identify particular patterns.

It is also conceivable that, in an unwinding device according to the invention, the arithmetic unit is in communication connection with an output unit and configured to output a visual and / or audible warning message via the output unit when the irregularity is detected or the irregularity of one is a predefined type of irregularity. The output unit may include, for example, a display, a light and / or a speaker to display or deliver the warning message. In this case, an operator of the unwinding device can be informed by means of a warning message, so that it is not necessary for him to keep an eye on the unwinding device, but nevertheless be informed about the output unit when a problem or a process-relevant event occurs.

According to a further aspect of the invention, an unwinding system for carrying out a unwinding process of a web material is claimed by a reel. Preferably, the unwinding process can be monitored by a monitoring method according to the invention. The unwinding system further comprises an unwinding device, which is preferably an unwinding device according to the invention. In this case, the unwinding device has a winding holder, on which the winding can be stored during the unwinding process, and a drive means, by which a propulsion of the web material can be generated, and a detection unit by which at least one irregularity of the web material and / or the unwinding process can be detected. The detection unit is in communication with a computer unit, wherein a correlation of the irregularity to at least one running parameter of the coil and can be determined by the arithmetic unit.

Thus, an unwinding system according to the invention brings about the same advantages as have been described in detail with reference to an unwinding device according to the invention and / or a monitoring method according to the invention.

Preferably, in an unwinding system according to the invention, an external server can be provided with a database which is in communication connection with the arithmetic unit, so that the correlation of the irregularity to the run parameter can be entered into the database via the communication interface. As a result, the unwinding system can be distributed over several locations, for example, and thus at least partially decouple the server from the unwinding device. Thus, the server can be located at an external service provider, so that, for example, several unwinding devices can communicate with the same server. This can be cost savings, if the server is not part the unwinding device, and on the other hand, several unwinding devices can use the same database to draw conclusions about causes of z. B. recurring irregularities to be able to produce with improved accuracy. Thus, the irregularities and running parameters or their correlation can also be assessed externally in order to draw conclusions from them. On the basis of these findings, a production method of web material and / or winding processes can then be improved.

Fig. 1:

ein erfindungsgemäßes Abwickelsystem mit einer erfindungsgemäßen Abwickelvorrichtung in schematischer Draufsicht in einem ersten Ausführungsbeispiel;

Fig. 2:

ein erfindungsgemäßes Abwickelsystem mit einer erfindungsgemäßen Abwickelvorrichtung in einem zweiten Ausführungsbeispiel in schematischer Draufsicht;

Fig. 3:

ein erfindungsgemäßes Überwachungsverfahren in schematischer Darstellung der Verfahrensschritte in einem dritten Ausführungsbeispiel;

Fig. 4 a-e:

eine weitere, schematische Darstellung von Verfahrensschritten des Überwachungsverfahrens des dritten Ausführungsbeispiels,

Fig. 5 a-c:

Beispiele von Unregelmäßigkeiten innerhalb eines Abwickelprozesses.

Further, measures improving the invention will become apparent from the following description of some embodiments of the invention, which are shown schematically in the figures. All of the claims, the description or the drawings resulting features and / or advantages, including constructive details, spatial arrangements and method steps may be essential to the invention, both in itself, and in various combinations. It should be noted that the figures have only descriptive character and are not intended to limit the invention in any way. Show it:

Fig. 1:

an inventive Abwickelsystem with an unwinding device according to the invention in a schematic plan view in a first embodiment;

Fig. 2:

an inventive Abwickelsystem with an unwinding device according to the invention in a second embodiment in a schematic plan view;

3:

an inventive monitoring method in a schematic representation of the method steps in a third embodiment;

Fig. 4 ae:

a further schematic representation of method steps of the monitoring method of the third embodiment,

Fig. 5 ac:

Examples of irregularities within an unwinding process.

In the following figures, the identical reference numerals are used for the same technical features of different embodiments.

FIG. 1 1 shows an unwinding system 5 according to the invention for carrying out a unwinding process of a web material 11 by means of an unwinding device 2. The unwinding device 2 comprises a winding holder 70 on which a reel 10 can be stored, or is stored during the unwinding process. In this case, the winding 10 comprises a winding tube 10.1 and at least partially a web material 11. During the unwinding process, the web material 11 is removed substantially flat from the winding 10. In this case, the winding holder 70 is adapted to rotatably support the winding 10, so that the winding 10 rotates during the development of the web material 11 accordingly. In order to realize a propulsion 11.1 of the web material 11, a drive means 50 is further provided. The drive means 50 can be designed, for example, to rotate the roll 10 and / or comprise a drive roll 51 which rolls with the sheet material 11 to thereby pull the sheet material 11 from the roll 10. As a result, it can also be provided, for example, that the winding 10 is mounted only rotationally on the winding holder 70, so that the rotation can be realized from a preference by the drive rollers 51. Furthermore, a detection unit 20 is provided, by which at least one irregularity 12 of the web material 11 and / or the unwinding process can be detected. The irregularity 12 is in FIG. 1 shown as missing a printed image. The detection unit 20 therefore comprises a camera for optical detection of the web material 11 and the irregularity 12. Furthermore, a measuring unit 21 is provided, by which the propulsion 11.1 of the web material 11 can be detected and a measurement of a number of revolutions 11.2 of the coil 10 is possible. The detection unit 20 and the measuring unit 21 are in communication with a computing unit 30, so that a correlation between the irregularity 12 and a running parameter 13 can be determined by the computing unit 30. For example, the running parameter 13 may include a length of the unwound web material 11 to irregularity 12 and / or a length of the web material 11 to the end of the irregularity 12. Thereby, a position of the irregularity 12 on the web material 11 with respect to the winding 10 can be determined. The arithmetic unit 30 also has a communication interface 31 in order to be able to enter the irregularity 12 into a database 40 in correlation with the run parameter 13. In this case, the database 40 is as Part of an internal memory unit 41 of the unwinding device 2 is provided and is preferably directly wired wired to the arithmetic unit 30 via the communication interface 31 in connection. The computer unit 30 can preferably execute a computer program, by means of which the correlation between the irregularity 12 and the run parameter 13 can be established. Preferably, the correlation may arise from the fact that the run parameter 13 with the irregularity 12 is registered with the irregular data 12 in the database 40 by the arithmetic unit 30. The correlation allows a conclusion to a manufacturing process of the roll 10 and / or on the unwinding process. Thus, in particular in the winding 10, the irregularity 12 can be localized. In this case, an occurrence of a certain irregularity 12 in the core can, for example, suggest that the winding 10 has been wound too hard. In addition, the arithmetic unit 30 is in communication with an output unit 60, so that a visual and / or audible warning message can be output via the output unit 60 when the irregularity 12 is detected or the irregularity 12 is of a predefined irregularity type. For example, the irregularity 12 may be defined such that a printed image is missing over a certain length of the web material 11 and in this case a warning message is output to the output unit 60. To output the warning message, the output unit 60 may include a wide variety of output means. Thus, a light source 62 and / or a loudspeaker 63 can be provided for outputting the warning message. Preferably, the output unit 60 further comprises a display 61 on which, on the one hand, different parameters of the unwinding process can be displayed and, on the other hand, the warning message can be output. Instead of the absence of the printed image, further types of irregularity come into consideration. Thus, also different types of irregularity can be detected by the detection unit 20. Furthermore, the detection unit 20 may additionally or alternatively comprise measuring means for measuring a force or a torque of the coil 10 and / or the sheet material 11. Further, exemplary types of irregularity are further in the FIGS. 5a to 5c shown. The computer unit 30 may also preferably carry out a determination of a number of products produced from the web material 11, so that these are determined instead of a count on the basis of the running parameter 13 and thus the number can be assigned to the reel 10. In particular, can thus by the Unwinding device 2 of the unwinding system 5, a quantification method for determining the number of the web material 11 produced products be feasible.

FIG. 2 shows an inventive unwinding system 5 for performing a unwinding process of a web material 11 of a winding 10. In this case, the unwinding system 5 corresponds to the FIG. 2 of the second embodiment substantially the unwinding system 5 of the first embodiment. Instead of an internal storage unit of an unwinding device 2 of the unwinding system 5, however, an external server 42 is provided which has a database 40. The server 42 is in communication with a computing unit 30, so that a correlation of an irregularity 12 to a run parameter 13 can be entered into the database 40 via a communication interface 31. The communication interface 31 may include, for example, an Internet access, which may be configured wired and / or wireless. For example, the unwinding device 2 may comprise a SIM card in order to establish a communication link with the external server 42. Because the external server 42 is outsourced, several unwinding devices 2 can be in communication with the server 42 in order to be able to concentrate the collected data and possibly associate it. As a result, further knowledge about the occurrence of the irregularities can be obtained and / or the accuracy of statements made thereby can be improved. Furthermore, the external server 42 can be cost effective for the unwinding device 2, as this the database 40 z. B. itself does not have and thus an additional internal storage unit is not necessary or can be used for redundancy to improve data security. In particular, by the unwinding system 5 according to FIG. 2 a quantification method for determining a number of products produced from the web material 11 may be feasible.

FIG. 3 shows a monitoring method 100 according to the invention for monitoring an unwinding process of an unwinding device 2 in a further exemplary embodiment in a schematic representation of the method steps. In this case, the monitoring method 100 comprises an at least partial unwinding 101 of a web material 11 from a reel 10, as also in FIG FIG. 4a is shown. In this case, the propulsion 11.1 can be realized, for example, by a drive means 50 of an unwinding device 2 become. In addition, the monitoring method 100 comprises detecting 102 at least one irregularity 12 of the web material 11 and / or the unwinding process. Thus, during unwinding of the web material 11 from the reel 10 by a detection unit 20 it can be determined that a certain process parameter deviates. This can be, for example, the fading of a printed image, so that in particular the region of the irregularity 12 is detected as such. Furthermore, a determination 103 of a correlation between the irregularity 12 and at least one running parameter 13 of the roll 10 is provided. The running parameter 13 may, for. Example, a length 13 to the beginning of the irregularity 12 from the unwound end of the web material 11 and / or a length to the end of the irregularity 12. In particular, an average of the lengths may be formed and / or both lengths in correlation with the irregularity 12 are brought. Such a correlation is also, for example, in FIG. 4b wherein the correlation comprises an assignability of the irregularity 12 and the running parameter 13. Preferably, it may further be provided that the irregularity 12 is correlated with a time 14, so that the time of occurrence of the irregularity 12 in the unwinding process can be determined later. Thus, an entry 104 of the correlation can take place and / or the correlation can be established by entering the irregularity 12 and the run parameter, 13 into a database 40 or can already be prepared beforehand and entered into the database 40 accordingly. It is for example in Figure 4c illustrated that the detection unit 20 provides signals to a computing unit 30, which enters the irregularity 12 and the run parameter 13 in the database 40 via a communication section 31. Preferably, the database 40 is thus part of an unwinding system 5 and may be part of an internal storage unit 41 of an unwinding device 2 or, as in FIG Figure 4c shown to be provided on an external server 42. Preferably, the monitoring method 100 further includes visually and / or audibly outputting a warning message 105 when the irregularity 12 is detected or the irregularity 12 is of a predefined irregularity type. The visual and / or acoustic output 105 is further in FIG FIG. 4d illustrated, wherein a lighting means 62 of a display unit 60 is provided to visually output the warning message and a speaker 63 is provided to output the warning message acoustically. Further advantages arise when the method 100 visualizes 106 the correlation between the irregularity 12 and the Running parameter 13 includes. Such a visualization 106 is in the Figure 4e represented, for example, a graph on a display 61 of the output unit 60 can be displayed, which plots a process parameter against a running parameter 13. In the illustrated exemplary embodiment, the process parameter is preferably a transparency of a printed image, although various other types of process parameters are conceivable here. As shown, a parameter range 16 may be provided which is defined by at least one parameter limit 16.1, preferably by two parameter limits 16.1, 16.2. If the process parameter exceeds one of the parameter limits 16.1 or falls below one of the parameter limits 16.2, an anomaly 12 is assumed. In this context, a plurality of irregularities 12, 12. 1 in the context of visualization 106 can also be correlated with a plurality of values 13. 1, 13. 2 of the run parameter 13 and displayed in the graph. Thus, furthermore, a determination 107 of a probability of an association of the irregularity 12 with a production process of the web material 11 and / or with the unwinding process can be carried out. Thus, for example, another area may be defined in which an occurrence of the irregularities 12, 12.1 speaks for a cause in the production process of the web material 11 and an occurrence of an irregularity 12 outside this area for a cause in the unwinding process. Preferably, the determination 107 of the probability can be carried out automatically, so that a degree of automation of the method is further increased, and thus costs can be saved and a reproducibility is improved. In particular, with the monitoring method 100 and / or individual method steps of the monitoring method 100, a quantification method for determining a number of products produced from the web material 11 may be feasible.

The FIGS. 5a to 5c show more types of irregularities. So shows FIG. 5a For example, the formation of a crack in the web material 11, which is optically detectable by a detection unit 20. Thus, for example, a certain length of a crack may be tolerable and classified as an irregularity 12 from a certain length of the crack. FIG. 5b also shows another possible irregularity 12, wherein a drive means 50 comprises drive rollers 51, which provide a propulsion 11.1 of the web material 11. If it is determined by a detection unit 20, for example, that a preference parameter 51.1 deviates from a desired value, an increased slip on the drive rollers 51 can be detected and thus define an irregularity 12. The slip may include, for example, a difference between an actual propulsion of the web material 11 and the preference parameter 51.1. FIG. 5c further shows an opening of a film tube, wherein the web material 11 is provided at least in a central region in two layers, which are connected to the outer sides of the web material 11. In order to bring the web material 11 in the form of a tube, it may be provided that aspirating means 52 in each case suck in and pull apart a surface of the web material 11 so that the tube is formed from the previously flat web material 11. By certain events within the process, it may happen that a suction force is not sufficient and the web material 11, for example, has blockages. As a result, it may not be possible by means of the suction means 52 to open the web material 11 at a specific location, wherein several aspiration attempts may be provided here. Several aspiration attempts can also be classified as irregularity 12 and reported to a computing unit 30. Thus, for example, a force measurement of the suction means 52 may be provided by the detection unit 20, wherein at an increased force or at a sudden drop in force this can be detected by the computing unit 30 as an irregularity 12.

The above explanation of the embodiment describes the present invention solely by way of examples. Of course, individual features of the embodiment, if technically feasible, can be combined freely with one another without departing from the scope of the present invention. In particular, a quantification method for determining a number of products produced from a web material with individual or all features of the embodiments, if technically expedient, can be combined.

LIST OF REFERENCE NUMBERS

2

unwinding

5

The unwind

10

reel

10.1

mandrel

11

sheeting

12

irregularity

13

running parameters

14

time specification

16

parameter range

16.1

first parameter limit

16.2

second parameter limit

20

acquisition unit

21

measuring unit

30

computer unit

31

Communication Interface

40

Database

41

internal storage unit

42

external server

50

drive means

51

capstan

52

suction

60

output unit

61

display

62

Lamp

63

speaker

70

winding support

100

monitoring procedures

101

At least partial unwinding

102

Capture 12

103

Determining a correlation

104

Enter in 40

105

Issue a warning message

106

Visualize the correlation

107

Determining a probability

Claims (15)

A monitoring method (100) for monitoring an unwinding process of an unwinding device (2), comprising the following steps: At least partially unwinding (101) a web material (11) from a roll (10), Detecting (102) at least one irregularity (12) of the web material (11) and / or the unwinding process, Determining (103) a correlation of the irregularity (12) to at least one running parameter (13) of the roll (10). A monitoring method (100) according to claim 1,
characterized,
in that the running parameter (13) is determined in particular continuously during unwinding (101) of the web material (11) from the reel (10). A monitoring method (100) according to claim 1 or 2,
characterized,
in that the running parameter (13) is determined by detecting a preferred parameter (51.1) on the web material (11), in particular wherein additionally a measurement of a number of revolutions (11.2) of the reel (10) is carried out. Monitoring method (100) according to one of the preceding claims,
characterized,
in that the monitoring method (100) further comprises the following step: - registering (104) the correlation of the irregularity (12) with the run parameter (13) in a database (40) and / or that the irregularity (12) is brought into a further correlation when entering the correlation in the database (40) with a time indication (14). Monitoring method (100) according to one of the preceding claims,
characterized,
in that the database (40) is provided on an external server (42) and / or an internal storage unit (41) of the unwinding device (2). Monitoring method (100) according to one of the preceding claims,
characterized,
in that the monitoring method (100) further comprises the following step: - visually and / or acoustically outputting (105) a warning message when the irregularity (12) is detected or the irregularity (12) is of a predefined type of irregularity. Monitoring method (100) according to one of the preceding claims,
characterized,
in that the monitoring method (100) further comprises the following step: Visualizing (106) the correlation of the irregularity (12) with the running parameter (13) and / or that the monitoring method (100) further comprises the step of: - Determining (107) a probability of a cause of the irregularity (12) in a manufacturing process of the web material (11) and / or in the unwinding process. Monitoring method (100) according to one of the preceding claims,
characterized,
that the irregularity (12) includes a process parameter that is outside a parameter region (16) and / or
that a number of from the web material (11) produced products is determined based on the running parameter (13). Unwinding device (2) for carrying out an unwinding process of a web material (11) from a reel (10), in particular wherein the unwinding process can be monitored by a monitoring method (100) according to one of the preceding claims
a winding holder (70) on which the roll (10) can be stored during the unwinding process,
a drive means (50), by which a drive (11.1) of the web material (11) can be generated,
and a detection unit (20), by which at least one irregularity (12) of the web material (11) and / or the unwinding process can be detected,
wherein the detection unit (20) is in communication communication with a computing unit (30), wherein a correlation of the irregularity (12) to at least one run parameter (13) of the roll (10) can be determined by the computing unit (30). Unwinding device (2) according to one of the preceding claims,
characterized,
in that the arithmetic unit (30) is in communication connection with a measuring unit (21) for detecting a preferred parameter (51.1) on the web material (11), in particular wherein the measuring unit (21) is additionally designed to measure a number of revolutions (11.2) of the reel (10) , Unwinding device (2) according to one of the preceding claims,
characterized,
that can be carried out by the arithmetic unit (30) a calculation of the running parameter (13). Unwinding device (2) according to one of the preceding claims,
characterized,
in that the arithmetic unit (30) has a communication interface (31) for data communication with a database (40), so that the correlation of the irregularity (12) to the run parameter (13) can be entered into the database (40) via the communication interface (31) , Unwinding device (2) according to one of the preceding claims,
characterized,
in that the arithmetic unit (30) is in communication communication with an output unit (60) and is adapted to output a visual and / or acoustic warning message via the output unit (60) when the irregularity (12) is detected or the irregularity (12) of a predefined type of irregularity. An unwinding system (5) for carrying out a unwinding process of a web material (11) from a reel (10), in particular wherein the unwinding process can be monitored by a monitoring method (100) according to one of claims 1 to 8
an unwinding device (2), in particular according to one of claims 9 to 13, with a winding holder (70) on which the reel (10) can be stored during the unwinding process,
a drive means (50), by which a drive (11.1) of the web material (11) can be generated,
and a detection unit (20), by which at least one irregularity (12) of the web material (11) and / or the unwinding process can be detected,
wherein the detection unit (20) is in communication communication with a computing unit (30), wherein a correlation of the irregularity (12) to at least one run parameter (13) of the roll (10) can be determined by the computing unit (30). Unwinding system (5) according to claim 14,
characterized,
that an external server (42) with a database (40) is provided with the calculating unit (30) is connected via a communication interface (31) in communication, so that the correlation of the irregularity (12) to the running parameters (13) in the Database (40) is registered.

Images