EP3741690A1

EP3741690A1 - Packaging machine of products for pourable food preparations

Info

Publication number: EP3741690A1
Application number: EP20176130.1A
Authority: EP
Inventors: Luca Cerati; Claudia DE MARIA; Alessandro CRISTOFORI; Antonio Vitali; Andrea Biondi
Original assignee: GD SpA
Current assignee: GD SpA
Priority date: 2019-05-24
Filing date: 2020-05-22
Publication date: 2020-11-25
Also published as: IT201900007201A1

Abstract

What is proposed is a packaging machine (1) for products (P) for pourable preparations, wherein each product (P) has two lateral walls (701) and two end walls (702; 703), the latter each being provided with a pair of folded triangular tabs (706), and is defined starting at least from a continuous web (M) of packaging material. The packaging machine (1) comprises a plurality of operating units (203; 206; 208; 210; 303) which are connected to each other such as at least one unwinding unit (203) for unwinding the web (M) from a reel (204); a sterilising unit for sterilising the unwound web (M); a longitudinal sealing unit (206) for sealing the sterilised web (M), configured for forming a continuous tube (207) along a sliding direction (D); a filling unit (208) configured for feeding the pourable food product into the continuous tube (207) formed; a forming and separating unit (210) configured for sealing the filled tube (11) along transversal seals (705) which are opposite each other relative to the longitudinal axis (D) of the tube (11) in such a way as to obtain a product (P), and for separating the product (P) from the tube by means of a transversal cut; a folding unit (303), configured for receiving the products (P) and for folding parts of the opposite transversal seals (705) of each product (P) thereby obtaining folded triangular tabs (706). The packaging machine (1) also comprises an acquisition device (501), configured for acquiring a data flow in the form of video or audio video streaming, comprising a sequence of frames acquired in sequence, relating to the products (P) being processed (1), and/or to the web (M) used to make those products (P) in one of the above-mentioned operating units (203; 206; 208; 210; 303) and a processing device (502) configured for comparing the data flow acquired by the acquisition device (501) with a reference data flow, for detecting any discontinuity in the acquired data flow.

Description

This invention relates to a packaging machine for products for pourable food preparations.
For many years disposable and/or re-closable products have been marketed which are made by folding and sealing a multi-layer wrapping sheet, that is to say, formed from layers of different materials coupled together, which are used for distributing pourable preparations. The term "pourable preparation" refers to a fluid preparation without its own shape, which adopts the shape of the object containing it and which may be a liquid or a preparation that is powdery, granular or semi-solid. These products may be, for example, used for distributing various types of food preparations (for example wine, milk, fruit juices, syrups, beverages, sauces, creams, yogurts, purees, preserves, vegetables, legumes, peeled items, etc.).
For example, the multi-layer wrapping sheet consists of an outer layer of transparent polyethylene (heat-sealable since it melts at relatively low temperatures), a subsequent supporting layer made of cardboard, a subsequent aluminium barrier layer, and an inner layer made of transparent polyethylene (heat-sealable since it melts at relatively low temperatures).
A common product for pourable preparations has the shape of a parallelepiped and has four lateral walls (in pairs parallel and opposite to each other) and two end walls respectively lower and upper which are perpendicular to the four lateral walls. The product comprises one longitudinal seal and two transversal seals, each of which is positioned at a respective end wall and has a seal portion which is initially perpendicular to the respective end wall and is then bent 90° against the end wall itself, or against a lateral wall.
Therefore, at the ends, each end wall has two folded triangular tabs. Typically, the triangular tabs at the upper end wall are folded against respective lateral walls, and fixed to the lateral walls themselves by means of heat-sealing, whilst the triangular tabs at the lower end wall are folded against the lower end wall itself, and are fixed to the lower end wall itself by means of heat-sealing.
The packaging machine for products for pourable preparations comprises a forming and filling part, which folds and heat-seals a continuous web of wrapping material, fed from a reel, and makes a tubular wrapper which is subsequently filled and separated to form products. The packaging machine additionally comprises a folding part which determines the final shape of the product.
The packaging machine comprises a plurality of operating units connected to each other and a control apparatus configured for controlling those operating units.
For example, the forming and filling part comprises an unwinding unit for unwinding the web from a reel, a sterilising unit for sterilising the web unwound, a longitudinal sealing unit for the sterilised web, which forms a continuous tube, a filling unit thanks to which the food preparation is poured into the continuous tube formed, a forming and separating unit capable of sealing the filled tube along transversal seal portions which are opposite each other relative to the longitudinal axis of the tube and separating the product from the sealed tube by means of a transversal cut. In detail, the longitudinal sealing unit comprises a folding device, in which the continuous web is vertically folded into a tube, and a longitudinal sealing unit, which longitudinally seals two opposite, superposed longitudinal edges so as to form a tube. The filling unit feeds the pourable preparation into the continuous tube formed, which is closed at the bottom and at the top by the forming and separating unit, which comprises two movable induction bars capable of making two respective transversal seals, which form two corresponding sealed zones, perpendicular to the end walls, and four triangular tabs, determining formation of the product which is initially "pillow"-shaped. The forming and separating unit is capable of cutting transversally, at the same time as or after production of the seals, the "pillow" just made. In addition, at the same time as or after the transversal seals are made, the forming and separating unit is capable of shaping the product, for example by means of a pair of hollow shells which compress the product between them, forcing it into a predefined shape, so that the product adopts a definitive parallelepiped shape.
The folding part comprises a folding unit, configured for receiving the products and for folding parts of the opposite seal portions of each product thereby obtaining the folded triangular tabs.
The folding unit, positioned downstream of the forming and separating unit, comprises a belt transfer conveyor, which receives the product following completion of product closing by means of the three seals (one longitudinal seal and two transversal seals) and inserts it into a pocket of a folding wheel, in which initially two transversal seals are folded 90° against the respective end walls and then the triangular tabs are folded against the corresponding lateral walls and/or against the corresponding end walls and then locked in the folded position by means of heat-sealing.
In general, prior art packaging machines, of the type described above, are not capable for reaching a high operating speed, measured as the number of products made in the unit of time, while simultaneously maintaining a high level of product quality, that is to say, extreme spatial precision when making the seals and the folds.
The extreme precision in the seals is essential for not compromising the sterility of the products made.
What may be particularly critical is the execution of the longitudinal sealing and movement of the heating bars relative to the tubular wrapper, since, if the longitudinal seal is imprecise and/or the heating bars brush on the web of wrapping material, longitudinal and transversal seals may be produced which are incorrect and there may be damage to the sealed zone, with consequent loss of sterility of the products.
However, imprecise execution of the longitudinal and/or transversal sealing could also depend on the poor quality of the web of material fed or on position imprecisions linked to web unwinding from a reel, causing the web to be fed to the longitudinal sealing unit in an incorrect position.
The extreme spatial precision in the folding is necessary to avoid compromising the appearance of the more or less coloured printed sections at the zones where different parts of the wrapping sheet are side by side and to avoid compromising the final shape of the product.
The transfer of products in the belt transfer conveyor, as well as their insertion into the folding wheel determines the precision of the final shape of the products at the folding wheel outfeed and the consequent final appearance of the products themselves.
The control apparatus runs a control program for such operating units, in order to carry out automated processes intended for making the products described above and/or for managing the web of wrapping material, setting new production formats, supervising production or scheduled maintenance of the operating units themselves.
In order to do that, the control apparatus runs the control program by reading the input data supplied by the field devices and by the sensors connected to each operating unit, analysing the packaging machine status resulting from those input data read and generating output data, based on these input data and on a control program logic, so as to make the operating units of the packaging machine operate.
Over the years increasingly complex industrial automation systems have been introduced in production plant comprising packaging machines for products containing pourable preparations, in order to reduce to the minimum indispensable any maintenance work, machine down times, and, above all, the number of products rejected due to loss of sterility and/or due to an aspect of the appearance of the products fed out of the packaging machine which does not comply with quality requirements. Loss of product sterility considerably reduces production efficiency due to the high number of products rejected but, above all, due to the lengthy machine down time necessary in order to carry out a cycle for restoring sterility and making the packaging machine operational again.
For that purpose, often, in addition to the control apparatus, there are also product quality analysis devices present which, locally, carry out parts of the whole industrial process or off-line test procedures and many automation components which, reading the data arriving from the analysis devices and from the control unit input data, modify, during packaging machine operation, some operating parameters of one or more operating units, with the aim of modifying the packaging machine functions and attempting to minimise malfunctions, consequently increasing the production efficiency of the packaging machine itself.
Despite the various product quality analysis devices or the various automation components described above, it might not be possible to identify production plant criticalities which risk a machine stoppage, or a lack of wrapping material quality, or absence of product sterility, or other risk factors, if such criticalities are not known in advance and there has been no identification of operating parameters to be modified in order to reduce or eliminate those criticalities.
In addition, although reading the data arriving from the analysis devices and from the control unit input data, there is often only a partial view of the criticalities and risk factors, given the large number of interdependencies and correlations between the input data of each unit of the packaging machine and the possibility that there may be hidden interdependencies present, which are difficult to identify even for an expert operator and designer.
The aim of this invention is to provide a packaging machine for products for pourable preparations which is free of the disadvantages described above and, at the same time, is easy and inexpensive to make.
Another aim of this invention is to provide a packaging machine which allows a high operating speed to be reached, at the same time maintaining a high level of product quality, both in terms of sterility and as regards their outer appearance.
Accordingly, this invention supplies a packaging machine for products for pourable preparations as set out in the appended independent claims. This invention will now be described with reference to the accompanying drawings, which illustrate an example, non-limiting embodiment of it, in which:

Figure 1 is a schematic view of a packaging machine for products for pourable preparations according to this invention comprising a plurality of operating units for processing the products being processed and the web of material used to make the products, a control apparatus for the operating units and a control unit for controlling packaging machine operation, and an acquisition device configured for acquiring a data flow in the form of video or audio video streaming;
Figure 2 is a perspective view of a product for pourable preparations;
Figure 3 is a perspective view, with parts cut away for clarity, of a forming and filling part of the packaging machine, which forms and fills the product starting from a web of wrapping material, and is made in accordance with this invention, comprising the acquisition device of Figure 1;
Figure 4 is a perspective view, with parts cut away for clarity, of a folding part, positioned downstream of the forming and filling part, which folds triangular tabs of the product for shaping a final shape of the product and is made in accordance with this invention, comprising the acquisition device of Figure 1;
Figure 5 is a schematic view of the acquisition device of Figure 1 and of a processing device configured for comparing the acquired data flow with a reference data flow, for detecting any possible discontinuity in the acquired data flow.

In Figure 1, the numeral 1 denotes in its entirety an automatic packaging machine for consumer products P, for example a packaging machine 1 for products P for pourable preparations which may be liquid, or semi-liquid, powdery, granular or semi-solid.
It should be noticed that the parts of the packaging machine 1 common to the packaging machine shown in Figures 1, 3 and 4 will be indicated with the same reference numbers.
In Figure 2 the term "P" indicates in its entirety a product for pourable preparations which contains a predetermined quantity of a pourable preparation. The definition of pourable preparation has been given previously and will not be repeated now. The product P is usually used for distributing pourable preparations of the food type.
The product P is made by folding and sealing a multi-layer wrapping sheet (that is to say, formed from layers of different materials coupled together) not illustrated. According to one possible, non-limiting embodiment, the wrapping sheet 2 consists of an outer layer of transparent polyethylene (heat-sealable since it melts at relatively low temperatures), a subsequent supporting layer made of cardboard, a subsequent aluminium barrier layer, and an inner layer made of transparent polyethylene (heat-sealable since it melts at relatively low temperatures). According to one possible, non-limiting embodiment, the wrapping sheet is provided in advance (usually by means of mechanical deformation performed with embossing rollers) with pre-weakened fold lines which guide the subsequent folding of the wrapping sheet.
As illustrated in Figure 2, the product P has the shape of a parallelepiped and has four lateral walls 701 (in pairs parallel and opposite to each other) and two end walls 702 and 703, respectively lower and upper, which are, preferably but not necessarily, perpendicular to the four lateral walls 701. The container 1 comprises one longitudinal seal 704 and two transversal seals 705, each of which is positioned at a respective end wall 702 or 703 and has a seal portion 706 which is initially perpendicular to the respective end wall 702 or 703 and is then bent 90° against the end wall 702 or 703 itself (as illustrated in Figure 1).
Each end wall 702 or 703 has (at the ends) a pair of folded triangular tabs 706 (also called "ears").
The triangular tabs 706 may be folded against respective lateral walls 701 or against the end wall 702 or 703 itself. Typically, as illustrated in Figure 1, the two triangular tabs 706 of the upper end wall 703 are folded against respective lateral walls 701 (and fixed to the lateral walls 701 themselves by means of heat-sealing), whilst the triangular tabs (not illustrated) of the lower end wall 703 are folded against the lower end wall 703 itself (and fixed to the lower end wall 703 itself by means of heat-sealing).
The packaging machine 1, of which a general operating diagram is shown in Figure 1, comprises a plurality of operating units configured for processing the products P and the materials M used to make those products P. For example, the packaging machine 1 comprises an infeed part 2 comprising a plurality of operating units made as drum conveyors 201, placed in sequence, configured for feeding and processing a web of material M, used to make the products P. The web of material M is, for example, fed from a reel (not illustrated).
Although in Figure 1 the material M used to make the products has been shown as a web, for example of a paper material, it should be noticed that the material used to make the products may be, for example, a paperboard blank intended to be folded.
The packaging machine 1 also comprises, by way of example, an outfeed part 3 configured for supplying the packaged products P, which comprises a respective operating unit, for example made as a linear conveyor 301 configured for feeding the products P, which comprises a planar conveying branch 302 on which the products P are placed resting on it and are conveyed towards a supplying outfeed (not illustrated). Between the infeed part 2 for feeding the material M used to make the products P and the outfeed part 3 for supplying the packaged products P, the packaging machine 1 comprises a packaging part for packaging the products P starting from the material M, not illustrated.
The packaging machine 1 comprises a control apparatus 4 configured for controlling the packaging machine 1, in particular the operating units 201, 301 of the packaging machine 1 which are indicated above. The control apparatus 4 is for example, a PLC, which runs a software program installed in the control apparatus 4 itself. That software program is configured for cyclically reading the input data supplied by field devices and by the sensors connected to each operating unit 201, 301, for analysing the packaging machine 1 status resulting from those input data read and for generating output data, based on these input data, so as to make the operating units 201, 301 of the packaging machine operate based on the control program.
The packaging machine 1 also comprises a control unit 5 for controlling operation of the packaging machine which comprises an acquisition device 501, configured for acquiring a data flow in the form of video streaming, or in the form of audio video streaming, that is to say, multi-media streaming, comprising a sequence of frames, that is to say, of images, acquired in sequence relating to the products P being processed in the packaging machine 1 and/or to the materials M used to make the products P.
The acquisition device 501 is, preferably, an image acquisition device, and optionally acquires sounds and images, at high speed and high resolution and the video, or audio video, flow acquired comprises a set of images, and optionally also of sounds, acquired in sequence which form the sequence of frames.
Hereinafter, for simplicity but without restricting the scope of the invention, the image acquisition device 501 shall be understood to be able to acquire either a video, or audio video, streaming data flow from an initial event E1 to a final event E2, as shown in Figure 5.
The initial event E1, that is to say, the start of the acquisition, like the final event E2, that is to say, the end of the acquisition, may be commanded by the control apparatus 4 of the packaging machine 1 and correspond to successive moments.
The image acquisition device may comprise a body on which an electronic sensor is positioned, for example an array or arrangement of linear or two-dimensional matrix light-sensitive elements of the CCD or CMOS type, and special optical receiver devices fixed to the body, for example, a lens through which the sensor can receive the diffused light to be acquired. It should be noticed that an image with a resolution of [nxm] pixels may be acquired by means of a single shot using a two-dimensional sensor with two-dimensional matrix of light-sensitive elements [nxm] or by means of n consecutive shots using a linear sensor with m light-sensitive elements. Preferably, the acquisition device 501 is configured for acquiring images in a wavelength range of from 100 nm to 15 µm.
In detail, the acquisition device 501 is configured for acquiring images which are in the following ranges: ultraviolet UV (100 - 400 nm), and/or visible (380 - 750 nm), and/or NIR - Near Infrared (750 nm - 1.4 µm), and/or SWIR - Short-wavelength infrared (1.4 µm - 3 µm) and/or MWIR - Medium Wavelength Infrared (3 - 8 µm), and/or LWIR - Long Wavelength Infrared (8 -15 µm) including image thermography.
The acquisition device 501 may, optionally, be configured for acquiring hyperspectral images included in a spectral range of between 400 nm and 4000 nm, preferably between 950 nm and 1700 nm, more preferable still included between 1250 nm and 1600 nm.
In addition, the control unit 5 comprises: a processing device 502, which is configured for comparing the acquired data flow with a reference data flow, for detecting any discontinuity in the acquired data flow.
The term discontinuity refers to an anomalous variation, or an unexpected irregularity, compared with the reference data flow.
For example, the unexpected irregularity may relate to a reference multi-media signal, which may be uniform or cyclically repetitive (video, or audio video) and may relate to correct operation of the packaging machine 1. However, the reference data flow may also be determined during a learning step, as described in detail below, as a whole and may not be linked to a specific correct operation of the packaging machine.
In other words, the discontinuity in the streaming data flow may highlight an anomalous operation of the packaging machine 1 relating to the products P being processed in the packaging machine 1 and/or to the materials M used to make the products P. For example, there is a discontinuity if a frame of the streaming data flow is not assessed to be acceptable relative to the reference data flow.
The control unit 5 also comprises a long-term memory 503. Indeed, the processing device 502 is configured for undertaking corrective actions based on the discontinuity detected and/or saving the acquired data flow in the long-term memory 503 following detection of the discontinuity for a subsequent assessment.
The control unit also comprises a temporary memory 504, for example a RAM memory, configured for saving the data flow acquired by the acquisition device 501.
Thanks to detection of a discontinuity in an acquired data flow, for example in a video, or audio and video, streaming relative to a reference data flow, an acquisition viewpoint is defined which is no longer dependent on the input data supplied by field devices and by the sensors connected to the operating units 201, 301, but instead is processed based on an external acquisition viewpoint, as if an expert machine operator were present, constantly observing the packaging machine itself, paying particular attention to the products P being processed in the packaging machine 1 and/or to the materials M used to make the products P.
The acquisition device 501 may be positioned facing a portion of packaging machine 1 comprising a plurality of operating units 201, 301, for example facing a specific operating unit 201 or 301, in such a way as to frame a field of view having a "context" which is known beforehand. The term "context" refers to the fact that, given a portion of the packaging machine 1 framed, the scenes acquired and the content of the videos acquired are already known beforehand and do not change over time.
In this way, the processing device 502 can detect the discontinuity in the acquired data flow, for example in the acquired video or audio video streaming, without adding filters relating to the significance of the acquired data flow itself. The "context" being known beforehand, the whole data flow is entirely analysable and therefore the processing is simplified. Advantageously, the acquisition device 501 may be positioned facing the portion of the packaging machine 1 from the front in an observation point in which a machine operator could be positioned for viewing or monitoring operation of the packaging machine 1.
Otherwise, the acquisition device 501 may be positioned facing the portion of the packaging machine 1, that is to say, facing the operating unit 201, or 301, but from the side rather than from the front, if it is appropriate to acquire the data flow from an observation point different from an observation point of an operator.
The packaging machine 1 may also comprise multiple acquisition devices 501, which are facing respective portions of packaging machine at respective observation points. It shall be understood that multiple acquisition devices 501 may be connected to the same processing device 502 or each acquisition device 501 may have a respective processing device 502 associated with it.
It should be noticed that the control unit 5 is connectable to the control apparatus 4 of the packaging machine 1 for receiving and/or supplying data and/or commands to the packaging machine 1 itself.
As already indicated, the acquisition device 501 is a video streaming image acquisition device, or an audio and video multi-media acquisition device, configured for acquiring the sequence of N frames, that is to say, of images, in sequence.
The sequence may be that of a continuous streaming or, alternatively, since it is connectable to the control apparatus 4 of the packaging machine 1, the sequence may be that which the acquisition device 501 can select amongst those of the continuous streaming.
For example, the acquisition device 501 may acquire images, and optionally sounds:

asynchronously relative to the packaging machine, that is to say, for example, at a periodic acquisition command;
synchronously with the packaging machine 1, that is to say, at packaging machine 1 significant events (for example, at one or more specific machine encoder degrees in each machine cycle, that is to say, "in phase" with machine cyclical operation).

In the case of asynchronous acquisition, if the periodic acquisition command has an acquisition frequency which is the maximum possible, this is continuous streaming (particular case of asynchronous acquisition with maximum acquisition frequency).
If the periodic acquisition command has a low acquisition frequency, a stroboscopic video, or audio video, acquisition is carried out, if it is at a high acquisition frequency an acquisition with slow motion effect is carried out (for example with a high number of fps "frames per second" - 100 fps rather than the usual 25 fps/30 fps).
The number of frames per second acquired may range, for example, from a minimum of 15 fps with low quality video streaming, to a maximum of 300fps for extremely high quality video streaming with slow motion effect. Moreover, also significant for video streaming quality is the number of pixels acquired per frame, which considering a pixel matrix [nxm] may range from 320x240 pixels/frame, for low quality video streaming, to 640x480 pixels/frame or 854x480 pixels per frame, for a medium quality video, up to 1280x720 (720p Standard HD) or 1920x1080 (1080p Full HD, also called 2K), in compliance with the most common proportions 4:3 and 16:9 (aspect ratio) of video formats.
The acquired data flow may therefore be produced using images, and optionally sounds, periodically acquired over time in sequence or using images, and optionally sounds, which are acquired in sequence and at packaging machine 1 significant events, as previously illustrated. Alternatively, the data flow may be acquired starting from one of the significant events if this is considered as the initial event E1 from which the streaming data flow is acquired, and is a continuous streaming.
For example, the video or audio video streaming data flow may be acquired at a start of a processing cycle for processing the products P, or processing of the materials M used to make those products P. For example, and as described in more detail below, the acquisition device 501 may be positioned facing from the front a filling unit for the pourable preparation and, for example, the streaming data flow may be activated immediately before the filling starts and may be deactivated when filling has ended.
The initial event E1 of the start of the acquisition, like the final event E2 of the end of the acquisition, may be commanded by the control apparatus 4 of the packaging machine 1, which also controls a movement of the product P in front of the acquisition device 501 itself, relative to the movement itself.
The control unit 5, when connected to the control apparatus 4, can modify the packaging machine 1 operation with respect to the discontinuity detected, for example to modify packaging machine 1 operating parameters associated with the operating units 201, 301.
However, alternatively, the control unit 5 can activate a dedicated screen page of an operator interface (HMI - Human Machine Interface) of the control apparatus 4 of the packaging machine 1 to show, for example to a machine operator, the video, or audio video, streaming saved in the long-term memory 503 after the discontinuity and highlighting the discontinuity detected, without modifying the operating parameters of the self-same packaging machine 1.
In this case, the subsequent assessment indicated above, may be carried out by an expert operator who has the opportunity to perform an off-line analysis of the audio and/or video flow showing the discontinuity detected. Similarly, the corrective actions which the processing device 502 may undertake, based on the discontinuity detected, may also relate to the detection logic itself. Indeed, the processing device may be configured for correcting a discontinuity detection logic, for example correcting a mathematical model for said discontinuity detection.
That correction may take place by adapting the mathematical model used and/or selecting a different mathematical model, for example selected from a library of mathematical models available, based on metrics detected from the streaming data flow.
For the purposes of discontinuity detection, the processing device 502 comprises a software component configured for analysing the acquired data flow which is installed in the processing device 502 itself. The times for processing the data flow must be limited in order to modify packaging machine 1 operation and/or the logic for detection of the discontinuity in the shortest possible time, so as to increase packaging machine 1 production efficiency.
According to a preferred embodiment, the data flow acquisition device 501 is separate from the processing device 502 in order to increase processing efficiency.
However, in a different embodiment, the acquisition device 501 and the processing device 502 may be integrated with each other but in any case their functions remain separate.
For that purpose, as illustrated in Figure 5, in order to compare the acquired data flow with a reference data flow the processing device 502 may comprise a first component 505 for carrying out, during a first analysing step, an analysis of the data flow, for detecting at least one metric of the data flow, and a second component 506 for carrying out, during a second detecting step, a detection of the discontinuity, analysing the metric detected by the first component, during the first analysing step, by means of the mathematical model for detection of the discontinuity. The first analysis of the analogue or digital video, or audio video, streaming may be carried out on the streaming data flow saved in the temporary memory 504.
By adopting the first component 505 and the second component 506, the analysis of the video, or audio video, streaming data flow can be rendered more efficient and guarantee high performance.
Looking in more detail at the first component 505, it comprises a converting module 505', configured for converting the video, or audio video, streaming data flow which comprises the sequence of N frames acquired in sequence from the initial event E1 to the final event E2, and for obtaining a vector field 505" indicating a direction of a movement and an intensity of the movement of a plurality of uniform zones of pixels in each frame relative to a base frame.
For an analysis of this type intended to obtain the intensity and direction of the movement, the base frame may correspond to the frame initially acquired at the initial event E1. Therefore, in each frame after the initial one, for each uniform zone of pixels, the intensity and the direction of the movement relative to the base frame will be assessed.
The first component 505 also comprises a statistics module 505'" for analysing, by means of a statistical analysis algorithm, during a statistical analysis step following the converting step, the vector field 505" and for identifying some significant parameters of each frame N, that is to say, the so-called metrics, obtaining a set of data having reduced dimensions, that is to say, a data matrix having the size B x N indicated with the number 507, wherein B indicates the number of metrics identified.
For example, significant metrics may be the kurtosis of the angle, or the average intensity of the vector field 505" (that is to say, the average intensity of the modulus of a movement vector).
The converting module 505' may, for example, be produced by means of an Optical Flow type algorithm, for example Dense Optical Flow, which is configured for considering the motion of an object in consecutive frames of a frequency of frames acquired in sequence and therefore to assess a movement over time between the object and the acquisition device 501, assessing the movement of the position of a same pixel over time relative to the position of the self-same pixel in the base frame.
Since, as already indicated, the context of the frames framed in the viewfinder does not change over time, advantageously, the converting module 505' can identify in each frame the plurality of uniform zones of pixels, that is to say, closed zones inside which there are pixels present which meet the uniformity criteria. These closed zones are also called voxels.
For each of these zones, the Optical Flow type algorithm can consider the movement vector, defined by a pair of values given by the direction of the movement and by the intensity of the movement relative to the same zone of the reference frame, for converting the frames, each defined by [nxm] pixels, and obtain the vector field 505" previously described.
It should be noticed that, if the number of the plurality of uniform zones (that is to say, the voxels) is V, then the vector field 505" has a number of values equal to V (number of voxels) x 2 (the direction and intensity of the movement of each voxel) x N (number of frames).
The statistical processing carried out by the statistics module 505'" on the vector field 505" allows a further reduction in the data associated with each frame in order to identify at least the significant metric of each frame N. Preferably, there are at least 2 metrics of each frame N and there may even be as many as 40.
Therefore, advantageously, following the processing carried out by the first component 505 during the first analysing step, it is possible to convert the video streaming data flow, comprising N frames each of which comprises a total number of pixels [nxm], into a matrix of metrics having a reduced size BxN, with more simple processing and analysis which can advantageously be analysed in shorter times by the second component 506, dedicated to detection of the discontinuity.
Thanks to the first analysing step carried out by the first component 505, the content of each frame is converted and is simplified, detecting a plurality of metrics which summarise the information content of the frame itself.
For detection of the discontinuity, the second component 506 comprises a classifying module 506' for classifying, during a classifying step, the metrics of each of the frames N of the video and/or audio video flow and an assessing module 506" for assessing, during an assessing step, whether each frame of the sequence should be considered acceptable, that is to say, "OK", or unacceptable, that is to say, "NO".
For classifying, the classifying module 506' may comprise an algorithm of the Support Vector Machine type, for example, with which it is possible to associate with each frame a point in a Cartesian plane, if there are two metrics and they are for example the kurtosis of the angle and the average intensity of the field, or in a space having K dimensions if there are more than 2 metrics and they are equal to K.
Taking into consideration only two metrics, each frame of the sequence of frames N of the streaming data flow may therefore be represented in the Cartesian plane gradually as it is acquired, in accordance with the Support Vector Machine algorithm.
Thanks to the classifying module 506', it is possible to consider multiple metrics simultaneously for each video frame, and to classify the video frame itself by means of complex criteria, which consider a combination of multiple metrics.
The result of the classifying module 506' is then processed by the assessing module 506", for the assessment of the acceptability of each frame, which considers the comparison with the reference data flow.
For that assessment, as the reference data flow, the assessing module 506" may take into consideration classifying maps, which identify sets of "OK" acceptable frames or sets of "NO" unacceptable frames, and assess whether the acquired frame is included in one of the classifying maps having acceptable frames, or in another of the maps having unacceptable frames.
The discontinuity in the acquired data flow is detected if one of the frames of the sequence belongs to an unacceptable frames classifying map.
The classifying maps are defined during a learning step which precedes an operating step of packaging machine operation.
Therefore, in order for the second component 506 to be able to effectively detect the discontinuity in the video, or audio video, data flow acquired during the operating step of packaging machine operation, it is necessary to ensure that said operating step is preceded by the learning step.
During the learning step, the acquisition device 501 is configured for acquiring video, or audio video, streaming data flows in a controlled way, so that the processing device 502 can process them by means of the first component 505 and a configuring module (non illustrated) of the second component 506 configured for configuring the classifying maps a posteriori.
The classifying module can request the decision of an operator for each acquired streaming data flow during the learning step.
Indeed, the configuring module can submit each acquired data flow to an operator and receive indications about the acceptability, or lack of acceptability, of the data flow and therefore of the N frames acquired.
For each streaming data flow of the learning step, the operator can assess the presence or absence of a discontinuity capable of introducing a defectiveness in the products P being processed in the packaging machine 1 and/or in the use of the materials M used to make the products P.
Therefore, during the learning step, it may be the operator who assesses each streaming data flow and classifies it as "OK" or "NO".
Alternatively, automatic methods may exist for configuring without a supervisor, which, during the learning step, are supplied with data flows that refer exclusively to correct operation of the packaging machine 1 and in which the deviation from them is assessed in statistical terms. Such automatic methods are faster, but less reliable.
Therefore, during the learning step, the configuring module can configure classifying criteria, identifying and aggregating sets of "OK" acceptable frames or sets of "NO" unacceptable frames, taking into consideration all of the frames of all of the streaming data flows, as acquired, and defining a reference data flow by aggregating the a posteriori assessment of all of the streaming data flows of the learning step, by the operator or by the automatic configuration methods.
Thanks to the learning step, the reference data flow is constructed a posteriori and may relate to packaging machine 1 operation which is correct, or incorrect if the decision of the operator is requested, or only correct if automatic configuration methods without a supervisor are used. In the case of the classifying module in which the classifying algorithm is of the Support Vector Machine type, the classifying criteria are classifying maps which define boundaries between acceptance and non-acceptance spaces and which may be acceptance and non-acceptance maps.
At the end of the learning step, the classifying maps having been configured, the assessing module 506" is capable of assessing each frame, automatically, verifying which classifying map the frame belongs to. By comparing each frame of the streaming data flow with the reference data flow, defined by means of the classifying maps, it is possible to identify the discontinuity in the acquired data flow. For example, there is discontinuity when a frame of the N frames of the streaming data flow belongs to a non-acceptance map.
It should be noticed that the classifying module 506' of the second component 506 may even alternatively be produced using Neural Network or Random Forest type algorithms which do not necessitate classifying maps.
However, even with algorithms of this type, the operating step of packaging machine operation must be preceded by the learning step, in which the operator assesses each streaming data flow and classifies it as "OK" or "NO", so that the assessing module 506" can define the classifying criteria necessary so that subsequently, during the operating step of operation, the processing device 502 can classify each frame as acceptable, or not, in automatic mode.
That is to say, even with different types of algorithms, it is necessary to define the reference data flow by means of the learning step in order to allow identification of the discontinuity in the acquired data flow.
If the processing device 502 is configured for correcting the discontinuity detection logic by correcting the mathematical model, for example, for that purpose the classifying module 506' and/or the assessing module 506" may be modified in order to carry out an even more precise assessment of the streaming data flow.
As shown in Figure 1, the acquisition device 501, the processing device 502, the long-term memory 503 and the temporary memory 504 of the control unit 5 are connected to each other and are also connected to the control apparatus 4 by means of a communication network 6, for example the Internet or the factory LAN (Local Area Network).
Indeed, it should be noticed that, in this application, terms such as "unit", "apparatus", "device", "component", "module" refer to one or more entities which are connected to, or form part of, an information technology apparatus with one or more specific functions, wherein such entities may be hardware, a combination of hardware and software, or exclusively software. For example, a component may be, without limitation, a process being executed on a processor, a processor, a hard disk unit, multiple storage units (optical or magnetic storage media) including a solid state storage unit; an information technology data item; a software program which can be run by a computer and / or a computer and/or a harware calculation unit as a programmable hardware component or an application in the internet cloud.
By way of example, both an application being run on an information technology server and the information technology server itself may be considered a component. One or more components may reside in an execution process and a component may be located on a computer and/or distributed between two or more computers. Moreover, the components as described herein may be executed by various computer-readable storage media having various data structures saved on them.
For example, the long-term memory 503, usually made using a set of hard disks, even SSD, could be saved in an Internet cloud and not physically reside in the same information technology component in which the processing device 502 resides.
Similarly, the first component 505 and the second component 506 of the processing device 502 may reside on different hardware specially designed in order to obtain distributed processing for an efficient analysis of the video, or audio video, streaming or in the same hardware but in processes which are separate from each other.
Now consider a packaging machine 1 for products P for pourable food preparations, for which a general description has already been provided and which will be illustrated in detail in Figures 3 and 4.
The packaging machine 1 comprises a forming and filling part, which has been labelled in its entirety in Figure 3 with the number 202, and a folding unit, positioned downstream of the forming and filling part 202, which has been labelled in its entirety in Figure 4 with the number 303.
The packaging machine 1 comprises an unwinding unit for unwinding a web M of wrapping material, for example a feed conveyor 203 from a reel 204 of the web M, which contains a sequence of wrapping sheets 205. The packaging machine 1 comprises a sterilising unit (not illustrated) for sterilising the web M unwound and a sealing unit 206 for the sterilised web M, which is longitudinal, which is configured for forming a continuous tube 207 along a sliding direction D, which corresponds to a longitudinal axis of the tube 207. The longitudinal sealing unit 206 is configured for folding the web M and for superposing one over the other, and sealing together, two opposite longitudinal edges of the web M of wrapping material.
Positioned downstream of the longitudinal sealing unit 206 there is a filling unit 208 configured for feeding the pourable food preparation into the continuous tube 207 formed. In detail, the filling unit 208 comprises a feed duct 209 which is coupled to the web M at the longitudinal sealing unit 206 and leads to the filling unit 208.
The packaging machine 1 comprises a forming and separating unit 210 configured for sealing the filled tube 207 along the transversal seals 705 which are opposite each other relative to the longitudinal axis D of the tube 207 in such a way as to obtain a product P, and also configured for separating the product P from the tube 207 by means of a transversal cut (not illustrated).
The forming and separating unit 210 comprises a respective transversal sealing unit 211, only schematically shown, which comprises a pair of sealing heads (not illustrated) provided with sealing bars, for example of the induction type, which are cyclically closed from opposite sides against the web M shaped like a tube 207 so as to clamp the web M between them and define the transversal seals 705.
The forming and separating unit 210 comprises cutting elements (not illustrated) integrated in the sealing heads, which at the same time make a transversal cut at each transversal seal so as to define a product P, which is still "pillow"-shaped. The forming and separating unit 210 also comprises a pair of hollow shells (not illustrated) which enclose and compress the product P between them, forcing it into a predefined shape, and which at the same time may shape the product P so that the product P adopts a definitive parallelepiped shape and has the four triangular tabs 706, which must subsequently be folded.
As illustrated in Figure 4, following completion of product P closing by means of the longitudinal seal 704 and the transversal seals 705, the product P is received by the folding unit 303 of the packaging machine 1. The folding unit 303 is configured for receiving the products P and for folding the triangular tabs 706 obtained from the opposite transversal seals 505 of each product P thereby obtaining folded triangular tabs 706. The folding unit 303 comprises a belt transfer conveyor 304 which receives each product P and a folding wheel 305 which folds the triangular tabs 706.
The transfer conveyor 304 has a plurality of pockets 306 which are cyclically moved forward with constant motion, that is to say, with a law of motion that provides for a continuous and constant movement, along a linear transfer path which is positioned angled upwards relative to the horizontal. The transfer conveyor 304 comprises a conveyor belt closed in a loop which has teeth protruding relative to the conveyor belt itself which define the pockets 26 between them. Each tooth, positioned behind the product P, pushes the product along the transfer path towards the folding wheel 305.
The folding wheel 305 is positioned vertically and rotates in steps, that is to say, with intermittent motion during which the pauses are between movements, around a horizontal axis of rotation A. The folding wheel 305 supports a plurality of peripheral pockets 307 which are radially oriented. Each product P is transferred from the transfer conveyor to one of the peripheral pockets 307 of the folding wheel
As can be seen in Figure 4, the transfer conveyor 304 receives each product P with the transversal seals 705 still perpendicular to the respective end walls 702, 703 and with the triangular tabs 705 still extended and coplanar with the respective end walls 702, 703.
During the forward movement of the product P in the folding wheel 305, the transversal seals 705 are folded 90° onto the end walls 702, 703 whilst the transversal tabs are folded 90° against the lateral walls 301 (like the upper transversal tabs) and/or are folded 180° against the end walls 702, 703.
When the forward movement of the product P on the folding wheel 305 ends, the product P has its final shape shown in Figure 2.
In accordance with this invention, the packaging machine 1 for products P for pourable preparations comprises an acquisition device 501, configured for acquiring a data flow, in particular at least in the form of video streaming, or in the form of audio video streaming, that is to say, multi-media streaming, relating to the products P being processed, and/or to the web (M) used to make the products P in one of the above-mentioned operating units, such as the unwinding unit 203 for unwinding the web M from the reel 204, the sterilising unit for sterilising the web M unwound, the longitudinal sealing unit 206 for the sterilised web M, the filling unit 208 for filling the continuous tube 207, the product P forming and separating unit 210 and the folding unit 303.
The packaging machine comprises a processing device 502 configured for comparing the data flow acquired by the acquisition device 501 with a reference data flow, which relates to correct operation of the packaging machine 1, for detecting any discontinuity in the acquired data flow.
The acquisition device 501, the processing device 502, the control unit 5 comprising the acquisition device 501 and the processing device 502, as well as the control apparatus 4 of the packaging machine 1 have been illustrated in detail with reference to the packaging machine schematically shown in Figure 1 and will not be described again in detail, except for those parts which differ from the parts already described.
Preferably, the acquisition device 501 is positioned facing one of the operating units 203, 206, 208, 210, 303, amongst the operating units present in the packaging machine 1, in such a way as to frame a portion of the operating unit and associate the discontinuity detected in the acquired data flow with the framed portion. In particular, the acquisition device 501 is positioned facing the operating unit of interest from the front in an observation point in which a machine operator could be positioned for viewing or monitoring operation of the operating unit.
The packaging machine may also comprise a plurality of acquisition devices 501, each positioned so as to frame a different operating unit amongst the operating units 203, 206, 208, 210, 303 or different portions of the same operating unit, for example, for detecting discontinuities in different portions of it.
It should be noticed that the if the acquisition device 501 is positioned facing any of the operating units selected in the forming and filling part 202 of the packaging machine 1, that is to say, any one amongst: the unwinding unit 203 for unwinding the web M from the reel 204, the sterilising unit for sterilising the web M unwound, the longitudinal sealing unit 206 for the sterilised web M, the filling unit 208 for filling the continuous tube 207, the forming and separating unit 210 for forming the product P and separating it from the continuous tube 207, the processing device 502 is configured for detecting a discontinuity linked to a loss of sterility in the packaging of the products P.
If the acquisition device 501 is positioned so that it frames the unwinding unit 203, the processing device 502 can detect a discontinuity in the acquired video, or audio video, data flow due to the web M of material unwound from the reel 204.
For example, the edges of the web M of material may become damaged during reel 204 storage before it is used. In this way, by positioning the acquisition device 501 facing the unwinding unit, it is possible to detect a discontinuity linked to the poor quality of the web M of material. Indeed, the poor quality of the web M of material may result in its erratic unwinding, for example with lateral slipping of the web M unwound, which, in turn, may affect the quality of the longitudinal seal made by the longitudinal sealing unit 206, positioned downstream of the unwinding unit 203, and therefore may cause the loss of sterility of the products P made. Moreover, if the acquisition device 501 is positioned facing and framing the longitudinal sealing unit 206, as in Figure 3, the processing device 502 can detect a discontinuity in the acquired video, or audio video, data flow linked to the sealed continuous tube 207.
For example, the discontinuity may relate to an anomalous behaviour of the longitudinal sealing unit 206 capable of directly compromising the longitudinal seal 704 and therefore the sterility of the products P.
The same considerations may be applied if the acquisition device 501 is positioned facing the forming and separating unit 210 for forming the product P and separating it from the continuous tube 207, since the processing device 502 may detect discontinuities linked to the transversal seals 705, which, again in this case, directly affect the sterility of the products P made.
If, in contrast, the acquisition device 501 is positioned facing the folding unit 303, in Figure 4, the processing device 502 is configured for detecting a discontinuity linked to an incorrect folding of the folded triangular tabs 706 and/or an incorrect shape configuration of each product (P).
The acquisition device 501 may be positioned facing the operating unit 203, 206, 208, 210, 303 from the front in an observation point in which a machine operator could be positioned for viewing or monitoring operation of the operating unit 203, 206, 208, 210, 303 itself.
In the case of the packaging machine 1 for products P for pourable preparations, the control apparatus 4 is configured for controlling the operating units 203, 206, 208, 210, 303 listed above. The control unit 5, which includes the acquisition device 501 and the processing device 502 for the video or audio video, data flow, is therefore connectable to the control apparatus 4 for receiving and/or supplying data and/or commands to packaging machine 1, that is to say, for modifying the operation of one of the operating units 203, 206, 208, 210, 303 of the packaging machine 1 based on the detected discontinuity.
As already indicated, if the discontinuity is detected in any amongst: the unwinding unit 203 for unwinding the web M from the reel 204, the sterilising unit for sterilising the web M unwound, the longitudinal sealing unit 206 for the sterilised web M, the filling unit 208 for filling the continuous tube 207, the forming and separating unit 210 for forming the product P and separating it from the continuous tube 207, the discontinuity is linked to a loss of sterility in the packaging of the products P. In this case, the control apparatus 5 may, for example, modify the operation of the packaging machine 1 stopping it to prevent production of products P which are not sterile.
If, in contrast, the discontinuity is linked to the folding unit 303, the control apparatus 5 may modify the operation of the packaging machine by rejecting each product P for which the discontinuity linked to incorrect folding of the triangular tabs 706 and/or to incorrect product shape has been detected.
If the discontinuity is linked to the filling unit 208 for filling the continuous tube 207, the control apparatus 5 may modify the operation of the packaging machine by rejecting each product P in which a filling error has been verified.
However, everything previously said still applies, that is to say, the control apparatus 4 modifying action may even only involve a modification of the operating parameters associated with the operating units 203, 206, 208, 210, 303.
Thanks to the processing device 502 it is possible to detect a discontinuity in the video flow of the operating units 203, 206, 208, 210, 303 and therefore it may be possible to avoid the production, destined to then be rejected, of products packaged in an atmosphere which is no longer protected, or having an inappropriate shape, with a significant increase in production efficiency.
In use, during the operating step of packaging machine operation, the acquisition device 501 of the packaging machine 1 for products P for pourable preparations disclosed in accordance with this invention, acquires a data flow, in particular in the form of video, or audio video, streaming, relating to the products P being processed in one of the operating units, such as the unwinding unit 203 for unwinding the web M from the reel 204, the sterilising unit for sterilising the web M unwound, the longitudinal sealing unit 206 for the sterilised web M, the filling unit 208 for filling the continuous tube 207, the product P forming and separating unit 210 and the folding unit 303 of the packaging machine 1 itself and/or relating to the web M of material used to make the products P. Comparing the acquired data flow with a reference data flow, which relates to correct operation of the packaging machine 1, therefore allows detection of any discontinuity in the acquired data flow and so allows identification of a malfunction which would otherwise not be visible, linked to behaviours which are hard to identify even with advanced sensors in one of the operating units 203, 206, 208, 210, 303 which are part of the packaging machine for products P for pourable preparations.
In use, the method for controlling operation of a packaging machine 1 for consumer products P comprises:

acquiring a data flow, in particular in the form of video, or audio video, streaming relating to the products P being processed in the packaging machine 1 and/or to the materials M used to make those products;
comparing the acquired data flow with a reference data flow, for detecting any discontinuity in the acquired data flow;
undertaking corrective actions based on the discontinuity detected and/or saving the acquired data flow in a long-term memory 503 following detection of the discontinuity for a subsequent assessment.

The method also comprises the further step of saving the acquired data flow in a temporary memory 504, for example a RAM memory.
As regards setting the reference data flow, the control method may comprise the further step of defining the reference data flow by means of a data flow previously saved in the temporary memory 504, for example relating to correct operation of the packaging machine 1, and/or receiving a reference start setting instruction from an operator and defining the reference data flow by means of the data flow acquired following that start setting instruction.
For example, the reference data flow may be that which, during a predetermined packaging machine 1 operating time period, corresponds to a maximum production efficiency of the packaging machine 1. If the packaging machine 1 is kept under observation for a time period which is longer, for example, than the predetermined period, amongst all of the acquired data flows it may be possible to select as the reference data flow the acquired data flow which corresponds to the best performance of the packaging machine 1 itself.
However, considering the fact that the processing device 502 may comprise the second component 506 dedicated to executing the mathematical model for detecting the discontinuity which necessitates the learning step, the reference start setting instruction may even correspond to the start of the learning step, since the data flows acquired during the learning step all contribute to defining the reference data flow to be considered during the packaging machine operating step. During the learning step, each acquired data flow may be saved in the temporary memory 504.
During the operating step of packaging machine operation, the step of comparing the acquired data flow with a reference data flow comprises a first step of analysing the data flow, for detecting at least one metric of the data flow, preferably a plurality of metrics of the data flow, and a second step of detecting the discontinuity, for analysing the metric detected during the first step and assessing the discontinuity in the acquired data flow relative to the reference data flow defined during the learning step, preceding the operating step of packaging machine operation.
The first analysing step comprises converting the video streaming data flow, comprising the sequence of N frames acquired in sequence, and obtaining a vector field 505" indicating, for each frame, a direction of a movement and an intensity of the movement of a plurality of uniform zones of pixels relative to a base frame. That converting step may be carried out by means of the Optical Flow algorithm.
The first step additionally comprises a statistical analysis step, following the converting step, for analysing the vector field 505" and for identifying at least one significant parameter of each frame N, preferably a plurality B of significant parameters of each frame, that is to say, the so-called metrics.
Thanks to the first analysing step, the content of each frame is converted and simplified, by detecting a plurality of metrics which summarise the information content of the frame itself.
The second step of detecting the discontinuity comprises a classifying step, for classifying the metric, or the plurality B of metrics of each of the frames N of the streaming data flow and an assessing step, following the classifying step, for assessing whether each frame of the sequence should be considered acceptable, that is to say, "OK", or unacceptable, that is to say, "NO" based on the classification of each metric.
The assessing step, during the packaging machine 1 operating step, comprises comparing each frame of the acquired streaming data flow with a reference data flow defined considering classifying maps, which identify sets of "OK" acceptable frames or sets of "NO" unacceptable frames, and assessing whether the frame is included in one of the classifying maps having acceptable frames, or in another of the maps having unacceptable frames.
The assessing step also comprises assessing the discontinuity in the acquired data flow if one of the frames of the sequence belongs to an unacceptable frames classifying map.
The method also comprises the step of defining the classifying maps during a learning step which precedes the operating step of packaging machine operation.
During the learning step, the method comprises the step of acquiring video, or audio video, streaming data flows, in a controlled way for allowing processing by means of the first analysing step and for obtaining the plurality of metrics and a configuring step for configuring the classifying maps a posteriori, after having obtained for all of the streaming data flows acquired during the learning step the decision from an operator, or from automatic configuration methods.
During the configuring step, the method according to this invention may comprise classifying the metrics of each of the frames N of the streaming data flow and, subsequently, submitting the acquired streaming data flow to an operator for receiving indications about the acceptability, or lack of acceptability, of the data flow and therefore of the N frames acquired. Alternatively, during the configuring step, the method according to this invention may comprise acquiring streaming data flows which all relate to correct operation of the packaging machine 1, classifying the metrics of each of the frames N of the streaming data flow and, subsequently, statistically analysing all of the acquired streaming data flows.
Therefore, the learning step comprises the further step of configuring the classifying maps, that is to say, the reference data flow, a posteriori, after the decision from the operator or the automatic configuration methods, identifying and aggregating sets of acceptable frames, or sets of unacceptable frames, taking into consideration all of the frames of all of the streaming data flows acquired during the learning step itself.
In detail, the step of undertaking corrective actions may comprise the step of modifying the operation of the packaging machine, for example modifying operating parameters of the packaging machine, or activating a correction of a mathematical model for detection of the discontinuity.
For example, if the acquisition of the video streaming relates to the filling unit 208 for filling the continuous tube 207, and the discontinuity detected is an incorrect filling due to excessive pressure used when pouring the pourable food product into the continuous tube 207, with respect to detection of the discontinuity in the streaming data flow, that is to say, with respect to detection of a non-optimal start of filling (splashes or diversion of the filling flow), there may be temporary reductions in the pourable product supply pressure and the packaging machine production speed. As already indicated, the correction may take place by adapting the mathematical model used and/or selecting a different mathematical model, for example selected from a library of mathematical models available, based on the metrics detected.
For example, the classifying module 506' of the second component 506 of the processing device 502 may be modified so as to deactivate classifying by means of Support Vector Machine, activating that using Neural Networks, if the discontinuity in the streaming data flow is more easily identifiable using the latter.
Indeed, there is the step of connecting to a network 6, for example the Internet, a control apparatus 4 for controlling the operating units 201, 301 of the packaging machine 1 and a control unit 5 for controlling packaging machine 1 operation, and there is the step of preparing a communication software in the control apparatus 4 and in the control unit 5 so that the control apparatus 4 receives any warnings about video, or audio video, streaming data flow discontinuity from the control unit 5 and the control unit 5 receives warnings about events indicative of packaging machine 1 operation from the control apparatus 4, for example the initial event E1 of acquisition of the streaming data flow and the final event E2 of stopping the acquisition.
The step of acquiring a data flow comprises the step of acquiring the sequence of images from the initial event E1 to the final event E2, asynchronously relative to the packaging machine 1, at a periodic acquisition command, or synchronously or in phase with events indicative of that operation, for example cyclical operating events.
Advantageously, the control method also comprises the further step of identifying at least one portion of packaging machine 1 comprising a plurality of operating units for packaging the products P and/or processing the materials M, and positioning an acquisition device, 501, configured for acquiring the video, or audio video, streaming data flow, facing the portion of packaging machine 1 identified, for example one of the operating units, for associating the discontinuity detected with said operating unit.
In particular the streaming data flow may be only video or audio video, that is to say, multi-media.
In other words, the control method may comprise the step of positioning the acquisition device 501 in the same observation point in which an expert machine operator could be positioned for viewing packaging machine 1 operation at the portion of machine identified.
The control method disclosed is configured as a smart supervising or monitoring of a complex operation such as that of a modern packaging machine with high production speed.
The control method disclosed allows easy control of the operation of a packaging machine in a non-traditional way, by considering a viewpoint outside the packaging machine by means of acquisition of a video, or audio video, flow in which to detect anomalous discontinuities or irregularities.
It should be noticed that, advantageously, the discontinuity detected may give rise to corrective actions on the packaging machine itself, but not only that, since the data flow may also advantageously be saved for an a posteriori control by an expert operator.

Claims

Packaging machine (1) for products (P) for pourable preparations, wherein each product (P) has four lateral walls (701) and two end walls (702; 703), the latter each being provided with a pair of folded triangular tabs (706), and is defined starting at least from a continuous web (M) of packaging material, said packaging machine (1) comprising a plurality of operating units (203; 206; 208; 210; 303) which are connected to each other such as:
- at least one unwinding unit (203) for unwinding the web (M) from a reel (204);

- a sterilising unit for sterilising the unwound web (M);

- a longitudinal sealing unit (206) for sealing the sterilised web (M), configured for forming a continuous tube (207) along a sliding direction (D);

- a filling unit (208) configured for feeding the pourable food product into the continuous tube (207) formed;

- a forming and separating unit (210) configured for sealing the filled tube (11) along transversal seals (705) which are opposite each other relative to the longitudinal axis (D) of the tube (11) in such a way as to obtain a product (P), and for separating the product (P) from the tube by means of a transversal cut;

- a folding unit (303), configured for receiving the products (P) and for folding parts of the opposite transversal seals (705) of each product (P) thereby obtaining folded triangular tabs (706); the packaging machine (1) being characterised in that it comprises

- an acquisition device (501), configured for acquiring a data flow in the form of video or audio video streaming, comprising a sequence of frames acquired in sequence, relating to the products (P) being processed (1), and/or to the web (M) used to make those products (P) in one of the above-mentioned operating units (203; 206; 208; 210; 303);

- a processing device (502) configured for comparing the data flow acquired by the acquisition device (501) with a reference data flow, for detecting any discontinuity in the acquired data flow.
The packaging machine according to claim 1, wherein the acquisition device (501) is positioned facing one of the operating units (203; 206; 208; 210; 303) in such a way as to frame at least one portion of the operating unit (203; 206; 208; 210; 303) for associating the discontinuity detected in the acquired data flow with said portion.
The packaging machine according to claim 2, wherein the acquisition device (501) is positioned facing the operating unit (203; 206; 208; 210; 303) from the front in an observation point in which a machine operator could be positioned for viewing or monitoring operation of the operating unit (203; 206; 208; 210; 303).
The packaging machine according to claim 2, or 3, wherein the acquisition device (501) is positioned facing any of the operating units selected from amongst: the unwinding unit (203) for unwinding the web (M), the sterilising unit for sterilising the unwound web (M), the longitudinal sealing unit (206) for sealing the sterilised web (M), the filling unit (208), the forming and separating unit (210); and wherein the processing device (502) is configured for detecting a discontinuity linked to a loss of sterility in the packaging of the products (P).
The packaging machine according to claim 4, wherein the acquisition device (501) is positioned facing the unwinding unit (203) and wherein the processing device (502) is configured for detecting a discontinuity due to the web (M) of material unwound from the reel (204).
The packaging machine according to claim 4, or 5, wherein the acquisition device (501) is positioned facing the longitudinal sealing unit (206) and wherein the processing device (502) is configured for detecting a discontinuity on the sealed continuous tube (207).
The packaging machine according to one of claims 4 to 6, wherein the acquisition device (501) is positioned facing the forming and separating unit (210) for forming the product (P) and separating it from the continuous tube (207) and wherein the processing device (502) is configured for detecting discontinuities linked to the transversal seals (705).
The packaging machine according to claim 2, or 3, wherein the acquisition device (501) is positioned facing the folding unit (303) and wherein the processing device (502) is configured for detecting a discontinuity linked to an incorrect folding of the folded triangular tabs (706) and/or an incorrect shape configuration of each product (P).
The packaging machine according to one or more of the preceding claims, and comprising a control apparatus (4) configured for controlling the operating units (203; 206; 208; 210; 303) and a control unit (5) which includes the acquisition device (501) and the processing device (502) for the video or audio video data flow, wherein the control unit (5) is connectable to the control apparatus (4) for modifying the operation of one of the operating units (203; 206; 208; 210; 303) of the packaging machine (1) based on the detected discontinuity.
The packaging machine according to claim 9, wherein the control unit (5) additionally comprises a long-term memory (503); the processing device (502) being configured for undertaking corrective actions based on the discontinuity detected and/or saving the acquired data flow in the long-term memory (503), following detection of the discontinuity, for a subsequent assessment.
The packaging machine according to claim 10, wherein the processing device (502) comprises a first component (505) for carrying out an analysis of the streaming data flow, for detecting at least one metric of the data flow, preferably a plurality of metrics, and a second component (506) for carrying out a detection of the discontinuity, analysing the metric, or the plurality of metrics, detected by the first component (505); the second component (506) comprising a classifying module (506') and an assessing module (506") and being configured for correcting a discontinuity detection logic, modifying a mathematical model for said discontinuity detection, modifying the classifying module (506') and/or the assessing module (506").
The packaging machine according to one or more of claims 9 to 11, when dependent on one of claims 4 to 7, wherein if the discontinuity detected is linked to a loss of sterility in the packaging of the products (P) in one of the operating units (203; 206; 208; 210), the control apparatus (5) is configured for stopping the packaging machine (1).
The packaging machine according to one or more of claims 9 to 11, when dependent on claim 8, wherein if the discontinuity detected is linked to the incorrect folding of the triangular tabs (706) and/or to the incorrect shaping of the product (P) itself in the folding unit (303), the control apparatus (5) is configured for rejecting each product (P) for which the discontinuity has been detected.
The packaging machine according to one or more of claims 9 to 13, wherein the control apparatus (5) is additionally configured for modifying the operation of one of the operating units (203; 206; 208; 210; 303) by modifying operating parameters of the self-same unit (203; 206; 208; 210; 303).
The packaging machine according to one or more of the preceding claims, wherein the acquisition device (501) is amongst: high speed and/or high resolution video cameras, which are configured for acquiring images in sequences in a wavelength range of from 100 nm to 15 µm and/or in a range of from 15 to 300 frames/sec.