EP4416564A1 - Method for regulating a system for the production and/or the packaging of consumer articles and relative system - Google Patents

Method for regulating a system for the production and/or the packaging of consumer articles and relative system

Info

Publication number
EP4416564A1
EP4416564A1 EP22800774.6A EP22800774A EP4416564A1 EP 4416564 A1 EP4416564 A1 EP 4416564A1 EP 22800774 A EP22800774 A EP 22800774A EP 4416564 A1 EP4416564 A1 EP 4416564A1
Authority
EP
European Patent Office
Prior art keywords
speed
machine
filling level
compensation
nominal speed
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
EP22800774.6A
Other languages
German (de)
French (fr)
Inventor
Matteo Degli Esposti
Massimiliano SEMATI
Gabriele Fabbri
Giuliano Gamberini
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
GD SpA
Original Assignee
GD SpA
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by GD SpA filed Critical GD SpA
Publication of EP4416564A1 publication Critical patent/EP4416564A1/en
Pending legal-status Critical Current

Links

Classifications

    • GPHYSICS
    • G05CONTROLLING; REGULATING
    • G05BCONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B19/00Program-control systems
    • G05B19/02Program-control systems electric
    • G05B19/418Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM]
    • G05B19/41865Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM] characterised by job scheduling, process planning, material flow
    • GPHYSICS
    • G05CONTROLLING; REGULATING
    • G05BCONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B2219/00Program-control systems
    • G05B2219/30Nc systems
    • G05B2219/31From computer integrated manufacturing till monitoring
    • G05B2219/31078Several machines and several buffers, storages, conveyors, robots
    • GPHYSICS
    • G05CONTROLLING; REGULATING
    • G05BCONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B2219/00Program-control systems
    • G05B2219/30Nc systems
    • G05B2219/32Operator till task planning
    • G05B2219/32265Waiting, queue time, buffer

Definitions

  • the invention relates to a method for regulating a system for the production or the packaging of consumer articles and to a relative system.
  • the invention finds advantageous, though non-limiting in a system of automatic machines for the production and the packaging of cigarette packs, to which explicit reference will be made in the description below without because of this losing in generality.
  • plants and systems for the production of smoking articles in a manufacturing environment of the tobacco processing industry comprise a plurality of operating machines connected to one another along a common production line.
  • the operating machines consist, going from upstream to downstream with reference to the aforesaid production line, of a maker or cigarette manufacturing machine, of a filter manufacturing machine, of a filter assembly machine, of a packer or cigarette pack packing machine, of a wrapping machine, of a cartoning machine and, finally, of a case packer capable of packing a plurality of cartons in packages, cases or boxes ready for delivery. Boxes are delivered with the aid of an end-of-line palletizer.
  • the aforesaid operating machines feature productive technologies that are extremely different from one another.
  • the product can be considered as a substantially continuous flow of cigarettes, unlike packers, cartoning machines and case packers, where the product definitely is discrete and well divided.
  • automatic machines such as makers require an operator for every machine standstill, who inserts the product (namely, a tobacco rod) as the maker machine progressively reaches the nominal production speed; on the contrary, discrete machines such as packers allow for a more automatic management of the product, since they can empty themselves, temporarily stop production and resume operation in complete autonomy.
  • the aforesaid buffer machines allow for the storage of millions of semi-finished products so as to allow the downstream machine (for instance, a packer) to continue production even in case of a stop of the upstream machine (for instance, a maker) and vice versa.
  • the buffer machine tends to empty itself until the upstream machine resumes production; in the second case, the buffer machine tends to fill itself until the upstream machine resumes production.
  • buffer machines In order to maintain a high efficiency of the production line, buffer machines currently have significant dimensions, which allow millions of products to be stored, thus ensuring productivity for several hours in case one of the operating machines stops.
  • Performance analysis production lines discrete and continuous flow models . described a production line with different servers.
  • the object of the invention is to provide a method for regulating a system for the production and/or the packaging of consumer articles, which is at least partially free from the drawbacks described above and, at the same time, is simple and economic to be carried out.
  • figure 1 shows a diagram of the structure of a line for the production of consumer articles according to a first embodiment of the invention
  • figure 2 shows, with the same criteria as figure 1, a diagram of the structure of a line for the production of consumer articles according to a preferred second embodiment of the invention
  • figure 3 shows a diagram of the control of a system for the management of the production or of the packaging of a consumer article according to an embodiment of the invention in different operating configurations;
  • figure 4 shows a diagram of the control of a system for the management of the production or of the packaging of a consumer article in a first operating configuration with a machine in standstill;
  • figure 5 shows a diagram of the control of a system for the management of the production or of the packaging of a consumer article in a second operating configuration with a machine in standstill.
  • number 1 indicates a system for the production and/or the packaging of consumer articles, for example articles of the tobacco industry such as cigarettes.
  • the system 1 comprises a plurality of automatic machines 2, 2’, 2” for the production and/or packaging of consumer articles arranged in series upstream and downstream of one another, respectively.
  • the machine 2 is a so- called maker
  • the machine 2’ is a so-called packer
  • the machine 2” is a so- called cartoning machine.
  • Other types of automatic machines or automatic machines of the kind described above can obviously be inserted in the series or the series itself can consists of two sole automatic machines 2, 2’, 2”.
  • upstream machine USM indicates a machine arranged, along a production path leading to the production and/or the packaging of the consumer article, before another machine called “downstream machine” DSM; in other words, the machine 2 is arranged upstream of the machines 2’, 2”, the machine 2” is arranged downstream of the machines 2, 2’ and the machine 2’ is arranged downstream of the machine 2 and upstream of the machine 2”.
  • automated machine defines an electromechanical system configured to receive, as an input, a first type of product and to provide another type of product as an output, after one or more processing operations, which cause at least one change thereof (for example, the addition of an element, the change of a shape, etcetera).
  • a conveyor belt should not be considered as an automatic machine, for it provides, as an output, the same product that it received as an input, without processing it.
  • processing a product means mechanically and/or chemically changing the structure thereof and/or at least carrying out tests.
  • processing an article should be considered as different from simply transporting it.
  • the system 1 advantageously comprises at least one storage element 3, which is arranged so as to be interposed between the upstream machine USM and the downstream machine DSM.
  • Each storage element 3 is configured to temporarily store the consumer articles being produced.
  • the storage element 3 is independent of the automatic machines 2, 2’, 2”, namely it constitutes, in turn, a buffer machine interposed between the operating machines 2, 2’, 2” of the series.
  • the storage element 3 is integrated in the upstream machine USM and/or in the downstream machine DSM. In this way, the dimensions of the storage element 3 can be relatively small, thus reducing costs and air exposure of the semi-finished articles.
  • At least one machine 2, 2’, 2” comprises a plurality of storage elements 3 integrated within it.
  • the storage element 3 is a tank following a chute (for example, following a station where the filter is applied or the rod is cut).
  • the storage element 3 is a so-called dynamic buffer, namely a container configured to change its shape and/or its capacity depending on the number of consumer articles present inside it.
  • the system 1 further comprises a detection device 4 arranged in the area of the storage element 3 and configured to detect the filling level FD of the storage element 3 itself.
  • the filling level FD indicates the quantity of consumer articles currently inside the storage element.
  • the detection device 4 can be any known sensor (of the physical or virtual kind, namely a counter) and, therefore, it will not be described in detail herein.
  • the system 1 further comprises a control unit 5, which is configured to operate the upstream machine USM so as to process the consumer articles at a first nominal speed NS and the downstream machine DSM so as to process the consumer articles at a second nominal speed NS2.
  • the nominal speed NS1 ideally corresponds to the nominal speed NS2 so that the storage elements 3 can have a substantially constant filling level FD.
  • control unit 5 comprises a plurality of logic units 6, 6’, each respectively associated with an automatic machine 2, 2’, 2” or with a storage element 3.
  • nominal speed means the speed at which the automatic machine moves during normal production, namely the set of speeds defining the law of motion executed during a normal cycle time of the automatic machine.
  • the nominal speed is the moving speed of a master axis of the automatic machine during a normal “steady” production.
  • the control unit 5 is preferably configured to control, depending on said filling level FD and for a limited compensation time, the automatic machine 2, 2’, 2” so as to process the consumer articles at a respective (upstream and/or downstream) compensation speed CVU and/or CVD, which is different from the nominal speed NS1 and/or from the nominal speed NS2, respectively.
  • “compensation speed” means a speed other than the nominal speed, namely different from the speed at which the automatic machine moves during normal production, namely different from the set of speeds defining the law of motion executed during a normal cycle time of the automatic machine.
  • the compensation speed is higher than the moving speed of a master axis of the automatic machine during a normal “steady” production.
  • the compensation speed is a speed that the automatic machine cannot bear for an indefinite amount of time maintaining the same efficiency as the nominal speed (in other words, it is a temporary overspeed of the automatic machine).
  • each storage element 3 has a respective logic unit 6’ configured to communicate with the logic units 6 of the upstream machine USM and of the downstream machine DSM.
  • the logic units 6 are configured to send, to the logic units 6’, state signals ST (for example, productive state, pause, error, production speed, etc.) of the (upstream or downstream) automatic machine 2, 2’, 2” and to receive, from the logic units 6’ of the storage elements 3, respective command signals CMD, which are configured to suggest the machine 2, 2’, 2” whether to continue producing at the respective nominal speed NS1, NS2 or, on the contrary, at the compensation speed CVU, CVD.
  • state signals ST for example, productive state, pause, error, production speed, etc.
  • each logic unit 6 since the elements 3 are integrated within the single automatic machines 2, 2’, 2”, each logic unit 6 also comprises the relative logic unit 6’ of the available storage elements 3 and the exchange of signals CMD, ST with the other machines 2, 2’, 2” becomes a two-way exchange, depending on the filling degree of the storage elements 3.
  • a same automatic machine 2, 2’, 2 in case it has intermediate storage elements 3 (like the machine 2 of figure 2), is ideally divided into several sections, each representing an upstream machine USM or a downstream machine DSM.
  • the control unit 5 can sent different productive, nominal and/or compensation speeds even within the same automatic machine 2, 2’, 2”.
  • each one of the storage elements 3 has a capacity that is such as to allow for a compensation time of less than 10 minutes, in particular less than 5 minutes.
  • the control unit 5 is preferably configured to control the filling level FD of the storage element 3 in real time, thus consequently controlling the machines 2, 2’, 2” in real time as described herein. In other words, the exchange of signals CMD, ST takes place in real time.
  • a method for regulating a system 1 for the production and/or the packaging of consumer articles is provided.
  • the method comprises at least the steps of:
  • the compensation speeds CVU, CVD of the upstream machine USM or of the downstream machine DSM are higher than the respective nominal speed NS1 and nominal speed NS2.
  • the compensation time is less than 10 minutes.
  • the control unit 5 controls at least one of the automatic machines 2, 2’, 2” of the series so that it produces under overspeed conditions.
  • the intermediate storage element 3 tends to fill; in case the downstream machine DSM is subject to overspeed (with the upstream machine USM at the speed NS 1), the intermediate element 3 tends to empty itself from the articles it contains.
  • the compensation speeds CVU, CVD of the upstream machine USM or of the downstream machine DSM are lower than the respective nominal speed NS1 and nominal speed NS2.
  • the control unit 5 controls at least one of the automatic machines 2, 2’, 2” of the series so that it produces under underspeed conditions.
  • the upstream machine USM is subject to underspeed (with the downstream machine DSM at the speed NS2)
  • the intermediate storage element 3 tends to empty itself; in case the downstream machine DSM is subject to underspeed (with the upstream machine USM at the speed NS1), the intermediate element 3 tends to fill with the articles it contains.
  • Figure 3 shows a non-limiting embodiment, wherein the filling level FD of the storage element 3 (for example expressed as a percentage) is correlated with five different operating configurations (relating to the production speed) between two machines 2, 2’, 2” of the series, in particular between an upstream machine USM and a downstream machine DSM.
  • the five different operating configurations are:
  • figure 3 shows the correlation between the operating configurations a)-e) and the filling level FD.
  • said correlation is indicated by the filling profile EP, if the storage element 3 is in a filling phase (namely, if the sign of the derivative of the filling level FD is positive), and by the emptying profile FP, if the storage element 3 is in an emptying phase (namely, if the sign of the derivative of the filling level FD is negative).
  • the compensation speeds CVU, CVD are controlled according to at least partially different profiles FP, EP depending on the sign of the derivative of the filling level, namely depending on whether the storage element 3 is being filled or emptied.
  • the profiles EP and FP do not overlap one another, namely there is not a strictly linear correlation between the current operating configuration a)-e) and the filling level FD of the storage element 3. Therefore, a single value of the filling level FD does not always necessarily correspond to the same operating configuration a)-e) and vice versa.
  • the profiles FP, EP preferably follow a hysteresis pattern, in particular a concatenated hysteresis pattern.
  • hysteresis pattern indicates a profile which, in a given instant, has a value that depends not only on the values of the filling level FD in that instant, but also on the ones it assumed in previous instants.
  • hysteresis involves a closed circuit profile (like the four rectangles delimited by the profiles EP and FP in figure 3).
  • the condition of normal productivity is indicated by the predefined desired value SP, which, in this example, is set at a filling level FD of 50%.
  • the upstream machine USM and the downstream machine DSM each produce at the respective nominal speed NS1, NS2 (preferably at the same speed, namely the downstream machine DSM processes the n products coming out of the upstream machine with a 1:1 ratio).
  • the downstream machine DSM is controlled so that the compensation speed CVD is higher than the nominal speed NS2 (namely, the control unit 5 controls the system 1 so that two machines 2, 2’, 2” take on operating condition b)).
  • the first threshold value 7 is the same as the predefined desired value SP (namely, a filling level FD of 50%), in case the storage element 3 is being emptied, namely along the profile EP; on the contrary, the first threshold value 7’ is greater than the predefined desired value SP (for example, with a filling level FD of 70%), in case the storage element 3 is being filled, namely along the profile FP.
  • the upstream machine USM is controlled so as to maintain the nominal speed NS1.
  • the upstream machine USM is controlled so as to stop (namely, the control unit 5 controls the system 1 so that two machines 2, 2,’, 2” take on operating configuration a)). More in particular, in other words, the upstream machine USM is controlled, firstly, so as to empty itself and, secondly, so as to stop.
  • the second threshold value 8 is greater than threshold value 7 (for example, with a filling level FD of 80%), in case the storage element 3 is being emptied, namely along the profile EP; similarly, the second threshold value 8’ is greater than the threshold value 7’ (for example, with a filling level FD of 90%), in case the storage element 3 is being filled, namely along the profile FP.
  • the upstream machine USM is controlled so that the compensation speed CVU is higher than the nominal speed NS2 (namely, the control unit 5 controls the system 1 so that two machines 2, 2’, 2” take on operating condition d)).
  • the third threshold value 9 is smaller than the predefined desired value SP (for example, with a filling level FD of 30%), in case the storage element 3 is being emptied, namely along the profile EP; on the contrary, the third threshold value 9’ is the same as the predefined desired value SP (namely, with a filling level FD of 50%), in case the storage element 3 is being filled, namely along the profile FP.
  • the upstream machine USM is controlled so as to maintain its nominal speed NS1.
  • the downstream machine DSM is controlled so as to stop (namely, the control unit 5 controls the system 1 so that two machines 2, 2,’, 2” take on operating configuration e)).
  • the fourth threshold value 10 is smaller than threshold value 9 (for example, with a filling level FD of 10%), in case the storage element 3 is being emptied, namely along the profile EP; similarly, the fourth threshold value 10’ is smaller than the threshold value 9’ (for example, with a filling level FD of 20%), in case the storage element 3 is being filled, namely along the profile FP.
  • the emptying profile EP preferably anticipates or coincides with the filling profile FP as the filling level FD increases.
  • the filling profile FP preferably anticipates or coincides with the emptying profile EP as the filling level FD decreases.
  • the predefined value SP and the values 7, 7’, 8, 8’, 9, 9’, 10, 10’ can obviously be different from the ones indicated above by mere way of example.
  • the predefined value SP and the values 7, 7’, 8, 8’, 9, 9’, 10, 10’ are determined in an empirical manner.
  • the predefined value SP and the values 7, 7’, 8, 8’, 9, 9’, 10, 10’ are determined according to statistic formulas and/or computerized simulations of the system 1 in relation to the levels of efficiency of each machine 2, 2’, 2”.
  • the predefined value SP and the values 7, 7’, 8, 8’, 9, 9’, 10, 10’ are determined by an artificial neural network trained with the productivity data of the machines 2, 2’, 2” of the system 1 or of systems that are similar to the system 1.
  • the upstream machine USM in a standstill condition of the downstream machine DSM, the upstream machine USM is controlled:
  • the fifth threshold value 11 corresponds to the second threshold value 8’ (for example, upon reaching of a filling level FD of 90%).
  • the downstream machine DSM in a standstill condition of the upstream machine USM, the downstream machine DSM is controlled:
  • the sixth threshold value 12 corresponds to the fourth threshold value 10 (for example, upon reaching of a filling level FD of 10%).
  • the system 1 comprises three (as shown in figures 1 and 2) or more automatic machines 2, 2’, 2” arranged in series, for which the aforesaid steps are repeated (preferably, for each pair of consecutive machines defining an upstream machine USM and a downstream machine DMS) in cascade.
  • system 1 is configured to carry out the method disclosed so far.
  • the invention offers many advantages.
  • the method described above reduces both consumption costs and maintenance costs of the so-called buffer machines, since they can be eliminated, like in the embodiment o figure 2.
  • the method and the system described above minimize harmful effects upon the efficiency of the line caused by the stop of a single machine.
  • the invention makes up, by means of a compensation speed that is higher than the nominal speed, for the time lost because of a delay or of a standstill of a machine of the line, keeping productivity (production time/number of articles produced) at predetermined levels.

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  • Engineering & Computer Science (AREA)
  • General Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Quality & Reliability (AREA)
  • Physics & Mathematics (AREA)
  • General Physics & Mathematics (AREA)
  • Automation & Control Theory (AREA)
  • Wrapping Of Specific Fragile Articles (AREA)
  • Auxiliary Devices For And Details Of Packaging Control (AREA)
  • General Factory Administration (AREA)

Abstract

Method for regulating a system (1) for the production and/or the packaging of consumer articles comprising at least a first and a second automatic machine (2, 2', 2"), arranged in series upstream and downstream respectively, for the production and/or the packaging of consumer articles; the method comprising the steps of: operating the first and second automatic machines (2, 2', 2") to process the articles at a first nominal speed (NS1) and at a second nominal speed (NS2); defining the filling level (FD) of an intermediate storage element (3) between the first and the second automatic machine (2, 2', 2"); controlling, depending on the said filling level (FD) and for a limited compensation time, the first and/or second automatic machine (2, 2', 2") to process the consumer articles at a respective first compensation speed (CVU) and/or second compensation speed (CVD), which are respectively different from the first nominal speed (NS1) and/or the second nominal speed (NS2).

Description

"Method for regulating a system for the production and/or the packaging of consumer articles and relative system "
Cross-Reference to Related Applications
This Patent Application claims priority from Italian Patent Application No. 102021000026480 filed on October 15, 2021, the entire disclosure of which is incorporated herein by reference.
Technical Sector
The invention relates to a method for regulating a system for the production or the packaging of consumer articles and to a relative system.
The invention finds advantageous, though non-limiting in a system of automatic machines for the production and the packaging of cigarette packs, to which explicit reference will be made in the description below without because of this losing in generality.
Prior Art
Generally speaking, plants and systems for the production of smoking articles in a manufacturing environment of the tobacco processing industry comprise a plurality of operating machines connected to one another along a common production line.
In particular, the operating machines consist, going from upstream to downstream with reference to the aforesaid production line, of a maker or cigarette manufacturing machine, of a filter manufacturing machine, of a filter assembly machine, of a packer or cigarette pack packing machine, of a wrapping machine, of a cartoning machine and, finally, of a case packer capable of packing a plurality of cartons in packages, cases or boxes ready for delivery. Boxes are delivered with the aid of an end-of-line palletizer.
The aforesaid operating machines feature productive technologies that are extremely different from one another. In the case of makers, the product can be considered as a substantially continuous flow of cigarettes, unlike packers, cartoning machines and case packers, where the product definitely is discrete and well divided. Furthermore, automatic machines such as makers require an operator for every machine standstill, who inserts the product (namely, a tobacco rod) as the maker machine progressively reaches the nominal production speed; on the contrary, discrete machines such as packers allow for a more automatic management of the product, since they can empty themselves, temporarily stop production and resume operation in complete autonomy.
Nowadays, in order to connect these different productive technologies, between an operating machine and the other, especially between the maker and the packer and between the packer and the wrapping machine, there are buffer or storage machines, which increase the efficiency of the system by allowing consecutive machines to have a productivity that is not constantly concordant. In particular, the aforesaid buffer machines allow for the storage of millions of semi-finished products so as to allow the downstream machine (for instance, a packer) to continue production even in case of a stop of the upstream machine (for instance, a maker) and vice versa. In the first case, the buffer machine tends to empty itself until the upstream machine resumes production; in the second case, the buffer machine tends to fill itself until the upstream machine resumes production.
In order to maintain a high efficiency of the production line, buffer machines currently have significant dimensions, which allow millions of products to be stored, thus ensuring productivity for several hours in case one of the operating machines stops.
However, these large-sized buffer machines significantly increase the costs to be borne for the supply of the line as wells as for the maintenance thereof and the relative consumption of energy. Furthermore, while being stored, the material present inside said buffer machines is exposed to the air of the factory, thus determining a risk of chemical contamination of the product and/or a loss or aroma.
Therefore, plants and systems for the production of smoking articles need to be improved taking into account the drawbacks discussed above.
Document US2015158676 discloses a conveyor machine, which places food articles incoming in blocks at predefined distances.
Document “ Performance analysis production lines: discrete and continuous flow models ” described a production line with different servers.
Description of the Invention
The object of the invention is to provide a method for regulating a system for the production and/or the packaging of consumer articles, which is at least partially free from the drawbacks described above and, at the same time, is simple and economic to be carried out.
According to the invention, there is provided a method for regulating a system for the production and/or the packaging of consumer articles according to the appended claims. There is also provided a relative production and/or packaging system.
The appended claims describe preferred embodiments of the invention and form an integral part of the description.
Brief Description of the Drawings
The invention will now be described with reference to the accompanying drawings, which show some non-limiting embodiments thereof, wherein:
• figure 1 shows a diagram of the structure of a line for the production of consumer articles according to a first embodiment of the invention;
• figure 2 shows, with the same criteria as figure 1, a diagram of the structure of a line for the production of consumer articles according to a preferred second embodiment of the invention;
• figure 3 shows a diagram of the control of a system for the management of the production or of the packaging of a consumer article according to an embodiment of the invention in different operating configurations;
• figure 4 shows a diagram of the control of a system for the management of the production or of the packaging of a consumer article in a first operating configuration with a machine in standstill; and
• figure 5 shows a diagram of the control of a system for the management of the production or of the packaging of a consumer article in a second operating configuration with a machine in standstill.
Preferred Embodiments of the Invention
In figures 1 and 2, number 1 indicates a system for the production and/or the packaging of consumer articles, for example articles of the tobacco industry such as cigarettes.
The system 1 comprises a plurality of automatic machines 2, 2’, 2” for the production and/or packaging of consumer articles arranged in series upstream and downstream of one another, respectively. For example, the machine 2 is a so- called maker, the machine 2’ is a so-called packer and the machine 2” is a so- called cartoning machine. Other types of automatic machines or automatic machines of the kind described above can obviously be inserted in the series or the series itself can consists of two sole automatic machines 2, 2’, 2”. Hereinafter, the term “upstream machine” USM indicates a machine arranged, along a production path leading to the production and/or the packaging of the consumer article, before another machine called “downstream machine” DSM; in other words, the machine 2 is arranged upstream of the machines 2’, 2”, the machine 2” is arranged downstream of the machines 2, 2’ and the machine 2’ is arranged downstream of the machine 2 and upstream of the machine 2”.
In particular, “automatic machine” defines an electromechanical system configured to receive, as an input, a first type of product and to provide another type of product as an output, after one or more processing operations, which cause at least one change thereof (for example, the addition of an element, the change of a shape, etcetera).
More precisely, a conveyor belt should not be considered as an automatic machine, for it provides, as an output, the same product that it received as an input, without processing it.
In particular, “processing a product” means mechanically and/or chemically changing the structure thereof and/or at least carrying out tests. As a matter of fact, processing an article should be considered as different from simply transporting it. The system 1 advantageously comprises at least one storage element 3, which is arranged so as to be interposed between the upstream machine USM and the downstream machine DSM. Each storage element 3 is configured to temporarily store the consumer articles being produced.
In the non-limiting embodiment of figure 1, the storage element 3 is independent of the automatic machines 2, 2’, 2”, namely it constitutes, in turn, a buffer machine interposed between the operating machines 2, 2’, 2” of the series.
In the non-limiting preferred embodiment of figure 2, the storage element 3 is integrated in the upstream machine USM and/or in the downstream machine DSM. In this way, the dimensions of the storage element 3 can be relatively small, thus reducing costs and air exposure of the semi-finished articles.
Advantageously, though not necessarily, as schematically shown in the nonlimiting embodiment of figure 2, at least one machine 2, 2’, 2” comprises a plurality of storage elements 3 integrated within it.
In some non-limiting cases, the storage element 3 is a tank following a chute (for example, following a station where the filter is applied or the rod is cut). Alternatively or in addition, the storage element 3 is a so-called dynamic buffer, namely a container configured to change its shape and/or its capacity depending on the number of consumer articles present inside it.
Advantageously, the system 1 further comprises a detection device 4 arranged in the area of the storage element 3 and configured to detect the filling level FD of the storage element 3 itself. Alternatively, the filling level FD indicates the quantity of consumer articles currently inside the storage element. The detection device 4 can be any known sensor (of the physical or virtual kind, namely a counter) and, therefore, it will not be described in detail herein.
The system 1 further comprises a control unit 5, which is configured to operate the upstream machine USM so as to process the consumer articles at a first nominal speed NS and the downstream machine DSM so as to process the consumer articles at a second nominal speed NS2. In particular, during a continuous production, the nominal speed NS1 ideally corresponds to the nominal speed NS2 so that the storage elements 3 can have a substantially constant filling level FD.
In some non-limiting cases, the control unit 5 comprises a plurality of logic units 6, 6’, each respectively associated with an automatic machine 2, 2’, 2” or with a storage element 3.
In particular, “nominal speed” means the speed at which the automatic machine moves during normal production, namely the set of speeds defining the law of motion executed during a normal cycle time of the automatic machine. For example, the nominal speed is the moving speed of a master axis of the automatic machine during a normal “steady” production.
The control unit 5 is preferably configured to control, depending on said filling level FD and for a limited compensation time, the automatic machine 2, 2’, 2” so as to process the consumer articles at a respective (upstream and/or downstream) compensation speed CVU and/or CVD, which is different from the nominal speed NS1 and/or from the nominal speed NS2, respectively. In particular, “compensation speed” means a speed other than the nominal speed, namely different from the speed at which the automatic machine moves during normal production, namely different from the set of speeds defining the law of motion executed during a normal cycle time of the automatic machine. For example, the compensation speed is higher than the moving speed of a master axis of the automatic machine during a normal “steady” production.
More in particular, the compensation speed is a speed that the automatic machine cannot bear for an indefinite amount of time maintaining the same efficiency as the nominal speed (in other words, it is a temporary overspeed of the automatic machine).
In the non-limiting embodiment of figure 1, each storage element 3 has a respective logic unit 6’ configured to communicate with the logic units 6 of the upstream machine USM and of the downstream machine DSM. In particular, the logic units 6 are configured to send, to the logic units 6’, state signals ST (for example, productive state, pause, error, production speed, etc.) of the (upstream or downstream) automatic machine 2, 2’, 2” and to receive, from the logic units 6’ of the storage elements 3, respective command signals CMD, which are configured to suggest the machine 2, 2’, 2” whether to continue producing at the respective nominal speed NS1, NS2 or, on the contrary, at the compensation speed CVU, CVD.
In the non-limiting embodiment of figure 2, since the elements 3 are integrated within the single automatic machines 2, 2’, 2”, each logic unit 6 also comprises the relative logic unit 6’ of the available storage elements 3 and the exchange of signals CMD, ST with the other machines 2, 2’, 2” becomes a two-way exchange, depending on the filling degree of the storage elements 3.
In some non-limiting cases, a same automatic machine 2, 2’, 2”, in case it has intermediate storage elements 3 (like the machine 2 of figure 2), is ideally divided into several sections, each representing an upstream machine USM or a downstream machine DSM. In other words, the control unit 5 can sent different productive, nominal and/or compensation speeds even within the same automatic machine 2, 2’, 2”.
Advantageously, though not necessarily, for example in the non-limiting embodiment of figure 2, each one of the storage elements 3 has a capacity that is such as to allow for a compensation time of less than 10 minutes, in particular less than 5 minutes.
The control unit 5 is preferably configured to control the filling level FD of the storage element 3 in real time, thus consequently controlling the machines 2, 2’, 2” in real time as described herein. In other words, the exchange of signals CMD, ST takes place in real time.
According to a further aspect of the invention, there is provided a method for regulating a system 1 for the production and/or the packaging of consumer articles.
The method comprises at least the steps of:
- operating at least two automatic machines 2, 2’, 2” (which can be considered one upstream or downstream of the other) so as to process the consumer articles at the nominal speed NS1 and at the nominal speed NS2, respectively;
- defining the filling level FD of the intermediate storage element 3 between the two automatic machines;
- controlling, depending on the said filling level FD and for a limited compensation time, at least one of the two automatic machines 2, 2’, 2” so as to process the consumer articles at a respective compensation speed CV, which is different from the nominal speed NS1 and/or from the nominal speed NS2, respectively.
Advantageously, though not necessarily, the compensation speeds CVU, CVD of the upstream machine USM or of the downstream machine DSM are higher than the respective nominal speed NS1 and nominal speed NS2. In particular, the compensation time is less than 10 minutes. In other words, in this case, the control unit 5 controls at least one of the automatic machines 2, 2’, 2” of the series so that it produces under overspeed conditions. In case the upstream machine USM is subject to overspeed (with the downstream machine DSM at the speed NS2), the intermediate storage element 3 tends to fill; in case the downstream machine DSM is subject to overspeed (with the upstream machine USM at the speed NS 1), the intermediate element 3 tends to empty itself from the articles it contains.
Alternatively or in addition, the compensation speeds CVU, CVD of the upstream machine USM or of the downstream machine DSM are lower than the respective nominal speed NS1 and nominal speed NS2. In other words, in this case, the control unit 5 controls at least one of the automatic machines 2, 2’, 2” of the series so that it produces under underspeed conditions. In case the upstream machine USM is subject to underspeed (with the downstream machine DSM at the speed NS2), the intermediate storage element 3 tends to empty itself; in case the downstream machine DSM is subject to underspeed (with the upstream machine USM at the speed NS1), the intermediate element 3 tends to fill with the articles it contains. Figure 3 shows a non-limiting embodiment, wherein the filling level FD of the storage element 3 (for example expressed as a percentage) is correlated with five different operating configurations (relating to the production speed) between two machines 2, 2’, 2” of the series, in particular between an upstream machine USM and a downstream machine DSM. In detail, the five different operating configurations are:
- NS1, NS2, wherein both the upstream machine USM and the downstream machine DSM are controlled at the respective nominal speeds; in this way, the filling level FD remains constant;
- NS1, CVD+, wherein the upstream machine USM is controlled at the respective nominal speed, whereas the downstream machine DSM is controlled with a positive compensation speed CVD (namely, under overspeed conditions); in this way, the filling level FD is reduced;
- SUS, CVD+, wherein the upstream machine USM is controlled so as to stop (with a stop command), whereas the downstream machine DSM is controlled with a positive compensation speed CVD (namely, under overspeed conditions); in this way, the filling level FD is strongly reduced;
- CVU+, NS2, wherein the downstream machine DSM is controlled at the respective nominal speed, whereas the upstream machine USM is controlled with a positive compensation speed CVU (namely, under overspeed conditions); in this way, the filling level FD is increased;
- CVU+, SDS, wherein the downstream machine DSM is controlled so as to stop (with a stop command), whereas the upstream machine USM is controlled with a positive compensation speed CVU (namely, under overspeed conditions); in this way, the filling level FD is strongly increased.
For greater convenience, the aforesaid operating configurations will be indicated with references a)-e) as shown in figure 3.
Therefore, figure 3 shows the correlation between the operating configurations a)-e) and the filling level FD. In particular, said correlation is indicated by the filling profile EP, if the storage element 3 is in a filling phase (namely, if the sign of the derivative of the filling level FD is positive), and by the emptying profile FP, if the storage element 3 is in an emptying phase (namely, if the sign of the derivative of the filling level FD is negative).
Advantageously, though not necessarily, as shown in the non-limiting embodiment of figure 5, the compensation speeds CVU, CVD are controlled according to at least partially different profiles FP, EP depending on the sign of the derivative of the filling level, namely depending on whether the storage element 3 is being filled or emptied. In other words, advantageously, though not necessarily, the profiles EP and FP do not overlap one another, namely there is not a strictly linear correlation between the current operating configuration a)-e) and the filling level FD of the storage element 3. Therefore, a single value of the filling level FD does not always necessarily correspond to the same operating configuration a)-e) and vice versa.
According to the non-limiting embodiment of figure 3, the profiles FP, EP preferably follow a hysteresis pattern, in particular a concatenated hysteresis pattern. The term “hysteresis pattern” indicates a profile which, in a given instant, has a value that depends not only on the values of the filling level FD in that instant, but also on the ones it assumed in previous instants. In particular, hysteresis involves a closed circuit profile (like the four rectangles delimited by the profiles EP and FP in figure 3).
In figure 3, the condition of normal productivity is indicated by the predefined desired value SP, which, in this example, is set at a filling level FD of 50%. In this configuration, namely operating configuration c), the upstream machine USM and the downstream machine DSM each produce at the respective nominal speed NS1, NS2 (preferably at the same speed, namely the downstream machine DSM processes the n products coming out of the upstream machine with a 1:1 ratio).
According to some non-limiting preferred cases, like the one of figure 3, if the filling level FD exceeds a first threshold value 7, 7’, which is greater than or equal to a predefined desired value SP, the downstream machine DSM is controlled so that the compensation speed CVD is higher than the nominal speed NS2 (namely, the control unit 5 controls the system 1 so that two machines 2, 2’, 2” take on operating condition b)). For instance, in the non-limiting embodiment of figure 3, the first threshold value 7 is the same as the predefined desired value SP (namely, a filling level FD of 50%), in case the storage element 3 is being emptied, namely along the profile EP; on the contrary, the first threshold value 7’ is greater than the predefined desired value SP (for example, with a filling level FD of 70%), in case the storage element 3 is being filled, namely along the profile FP.
Advantageously, though not necessarily, if the filling level FD ranges from the first threshold value 7, 7’ to a second threshold value 8, 8’ greater than the first threshold value 7, 7’, the upstream machine USM is controlled so as to maintain the nominal speed NS1. In particular, if the filling level FD of the storage element 3 exceeds the second threshold value 8, 8’, the upstream machine USM is controlled so as to stop (namely, the control unit 5 controls the system 1 so that two machines 2, 2,’, 2” take on operating configuration a)). More in particular, in other words, the upstream machine USM is controlled, firstly, so as to empty itself and, secondly, so as to stop.
For instance, in the non-limiting embodiment of figure 3, the second threshold value 8 is greater than threshold value 7 (for example, with a filling level FD of 80%), in case the storage element 3 is being emptied, namely along the profile EP; similarly, the second threshold value 8’ is greater than the threshold value 7’ (for example, with a filling level FD of 90%), in case the storage element 3 is being filled, namely along the profile FP.
Alternatively or in addition, advantageously, though not necessarily, if the filling level FD is smaller than a third threshold value 9, 9’, which is smaller than or equal to the predefined desired value SP, the upstream machine USM is controlled so that the compensation speed CVU is higher than the nominal speed NS2 (namely, the control unit 5 controls the system 1 so that two machines 2, 2’, 2” take on operating condition d)). For instance, in the non-limiting embodiment of figure 3, the third threshold value 9 is smaller than the predefined desired value SP (for example, with a filling level FD of 30%), in case the storage element 3 is being emptied, namely along the profile EP; on the contrary, the third threshold value 9’ is the same as the predefined desired value SP (namely, with a filling level FD of 50%), in case the storage element 3 is being filled, namely along the profile FP.
Advantageously, though not necessarily, if the filling level FD ranges from the third threshold value 9, 9’ to a fourth threshold value 10, 10’ smaller than the third threshold value 9, 9’, the upstream machine USM is controlled so as to maintain its nominal speed NS1. In particular, if the filling level FD is smaller than the fourth threshold value 10, 10’, the downstream machine DSM is controlled so as to stop (namely, the control unit 5 controls the system 1 so that two machines 2, 2,’, 2” take on operating configuration e)).
For instance, in the non-limiting embodiment of figure 3, the fourth threshold value 10 is smaller than threshold value 9 (for example, with a filling level FD of 10%), in case the storage element 3 is being emptied, namely along the profile EP; similarly, the fourth threshold value 10’ is smaller than the threshold value 9’ (for example, with a filling level FD of 20%), in case the storage element 3 is being filled, namely along the profile FP.
The emptying profile EP preferably anticipates or coincides with the filling profile FP as the filling level FD increases.
The filling profile FP preferably anticipates or coincides with the emptying profile EP as the filling level FD decreases.
The predefined value SP and the values 7, 7’, 8, 8’, 9, 9’, 10, 10’ can obviously be different from the ones indicated above by mere way of example.
In some non-limiting cases, the predefined value SP and the values 7, 7’, 8, 8’, 9, 9’, 10, 10’ are determined in an empirical manner.
In other non-limiting cases, the predefined value SP and the values 7, 7’, 8, 8’, 9, 9’, 10, 10’ are determined according to statistic formulas and/or computerized simulations of the system 1 in relation to the levels of efficiency of each machine 2, 2’, 2”.
In further non-limiting cases, or in addition to the previous ones, the predefined value SP and the values 7, 7’, 8, 8’, 9, 9’, 10, 10’ are determined by an artificial neural network trained with the productivity data of the machines 2, 2’, 2” of the system 1 or of systems that are similar to the system 1.
According to some preferred, though non-limiting embodiments, like the one shown in figure 4, in a standstill condition of the downstream machine DSM, the upstream machine USM is controlled:
- at the respective nominal speed NS1, if the filling level FD is lower than the predefined desired value SP (condition A)); or
- at a compensation speed CVU lower than the nominal speed NS1, if the filling level FD is higher than the predefined desired value SP (condition g)); or
- is stopped, if the filling level is higher than a fifth threshold value 11, which, in turn, is higher than the predefined desired value SP (condition h)).
Preferably, though not necessarily, the fifth threshold value 11 corresponds to the second threshold value 8’ (for example, upon reaching of a filling level FD of 90%).
According to some preferred, though non-limiting embodiments, like the one shown in figure 5, in a standstill condition of the upstream machine USM, the downstream machine DSM is controlled:
- at the respective nominal speed NS2, if the filling level FD is higher than the predefined desired value SP (condition / ); or
- at a compensation speed CVD lower than the nominal speed NS2, if the filling level FD is lower than the predefined desired value SP (condition j)); or
- is stopped, if the filling level is higher than a sixth threshold value 12, which, in turn, is lower than the predefined desired value SP (condition k)).
Preferably, though not necessarily, the sixth threshold value 12 corresponds to the fourth threshold value 10 (for example, upon reaching of a filling level FD of 10%).
Advantageously, though not necessarily, the system 1 comprises three (as shown in figures 1 and 2) or more automatic machines 2, 2’, 2” arranged in series, for which the aforesaid steps are repeated (preferably, for each pair of consecutive machines defining an upstream machine USM and a downstream machine DMS) in cascade.
Advantageously, though not necessarily, the system 1 is configured to carry out the method disclosed so far.
Even though the invention described above especially relates to a precise embodiment, it should not be considered as limited to this single embodiment, as its scope of protection comprises all those variants, changes or simplifications that would be evident for a person skilled in the art, such as for example: addition of further automatic machines, other types of automatic machines different from those of the tobacco industry, different shape of the filling and emptying profiles, different order of the steps of the method, different parameter to assess the filling of the storage element, etc.
The invention offers many advantages.
First of all, it avoids an excess storage of material between a machine and the following one, thus preventing said material from being exposed to air and, hence, significantly reducing the possibility of contamination and loss of freshness and aroma.
Furthermore, the method described above reduces both consumption costs and maintenance costs of the so-called buffer machines, since they can be eliminated, like in the embodiment o figure 2.
In addition, the method and the system described above minimize harmful effects upon the efficiency of the line caused by the stop of a single machine. By so doing, indeed, it is surprisingly possible to increase the line efficiency by a value ranging from 8% to 10% (or more), at least partially making up for the possible lack of suitable buffer machines.
Furthermore, the invention makes up, by means of a compensation speed that is higher than the nominal speed, for the time lost because of a delay or of a standstill of a machine of the line, keeping productivity (production time/number of articles produced) at predetermined levels.
Finally, since this is an algorithm that can be implemented via software, it can also be implemented in machines and systems that already exist and/or are manufactured by different manufacturers.

Claims

1) Method for regulating a system (1) for the production and/or the packaging of consumer articles; the system (1) comprising at least a first and a second automatic machine (2, 2', 2"), arranged in series upstream and downstream respectively, for the production and/or the packaging of consumer articles; the method comprising the steps of:
- operating the first and second automatic machines (2, 2', 2") to process the consumer articles at a first nominal speed (NS1) and a second nominal speed (NS2) respectively;
- defining the filling level (FD) of an intermediate storage element (3) between the first and the second automatic machine (2, 2', 2"), which temporarily accumulates the consumer articles under production;
- controlling, depending on the said filling level (FD) and for a limited compensation time, the first and/or second automatic machine (2, 2', 2") to process the consumer articles at a respective first compensation speed (CVU) and/or second compensation speed (CVD) which are respectively different from the first nominal speed (NS1) and/or the second nominal speed (NS2); wherein the first compensation speed (CVU) and/or the second compensation speed (CVD) are higher than the respective first nominal speed (NS1) and second nominal speed (NS 2).
2) Method according to claim 2, wherein the compensation time is less than 10 minutes.
3) Method according to claim 1 or 2, wherein the first compensation speed (CVU) and/or the second compensation speed (CVD) are lower than the respective first nominal speed (NS1) and second nominal speed (NS2).
4) Method according to any one of the preceding claims, wherein the first compensation speed (CVU) and/or the second compensation speed (CVD) are controlled according to at least partially different profiles (EP, FP) depending on the sign of the derivative of the filling level (FD), i.e., whether the storage element (3) is filling or emptying. 5) Method according to claim 4, wherein the at least partially different profiles (EP, FP), with respect to the filling level (FD) of the storage element (3), follow a hysteresis pattern, in particular a concatenated hysteresis pattern.
6) Method according to any one of the preceding claims, wherein if the filling level (FD) exceeds a first threshold value (7, 7'), which is greater than or equal to a desired predefined value (SP), the downstream machine (DSM) is controlled so that the second compensation speed (CVD) is higher than the second nominal speed (NS2).
7) Method according to claim 5, wherein if the filling level (FD) is between the first threshold value (7, 7') and a second threshold value (8, 8') greater than the first threshold value (7, 7'), the upstream machine (USM) is commanded to maintain the first nominal speed (NS1); wherein if the filling level (FD) exceeds the second threshold value (8, 8'), the upstream machine (USM) is commanded to stop.
8) Method according to any one of the preceding claims, wherein if the filling level (FD) is below a third threshold value (9, 9'), less than or equal to a desired predefined value (SP), the upstream machine (USM) is commanded so that the first compensation speed (CVU) is higher than the second nominal speed (NS2).
9) Method according to claim 8, wherein if the filling level (FD) is between the third threshold value (9, 9') and a fourth threshold value (10, 10') that is lower than the third threshold value (9, 9'), the upstream machine (USM) is commanded to maintain the first nominal speed (NS1); wherein if the filling level (FD) is lower than the fourth threshold value (10, 10'), the downstream machine (DSM) is commanded to stop.
10) Method according to any one of the preceding claims, wherein in a stop condition of the downstream machine (DSM), the upstream machine (USM) is commanded at the first nominal speed (NS1) if the filling level (FD) is lower than a desired predefined value (SP); or at a first compensation speed (CVU) lower than the first nominal speed (NS1) if the filling level (FD) is higher than 18 the desired predefined value (SP); or is stopped if the filling level (FD) is higher than a fifth threshold value (11), which is in turn higher than the desired predefined value (SP).
11) Method according to any one of the preceding claims, wherein in a stop condition of the upstream machine (USM), the downstream machine (DSM) is driven at a nominal second speed (NS2) if the filling level (FD) is higher than a desired predefined value (SP); or at a second compensation speed (CVD) lower than the nominal second speed (NS2) if the filling level (FD) is lower than the desired predefined value (SP); or is stopped if the filling level (FD) is lower than a sixth threshold value (12), which is in turn lower than the desired predefined value (SP).
12) Method according to any one of the preceding claims, wherein the system (1) comprises three or more automatic machines arranged in series and for which said steps are repeated in cascade.
13) System (1) for the production and/or the packaging of consumer articles comprising:
- at least one first and one second (2, 2', 2') automatic machine for the production and/or packaging of consumer articles arranged in series with each other upstream and downstream respectively;
- an intermediate storage element (3) between the first and the second automatic machine (2, 2', 2") configured to temporarily accumulate the articles of consumption in production;
- a detection device (4) arranged at the storage element (3) and configured to detect the filling level (FD) of the storage element (3) itself;
- a control unit (5) configured to control the first and the second automatic machine (2, 2', 2") to process the consumer articles respectively at a first nominal speed (NS1) and at a second nominal speed (NS2); wherein the control unit (5) is configured to control, depending on said filling level (FD) and for a limited compensation time, the first and/or the second automatic machine (2, 2', 2") to process the consumer articles at a respective first 19 compensation speed (CVU) and/or second compensation speed (CVD), which are respectively different from the first nominal speed (NS1) and/or the second nominal speed (NS 2); wherein the first compensation speed (CVU) and/or the second compensation speed (CVD) are higher than the respective first nominal speed (NS1) and second nominal speed (NS 2).
14) System (1) according to claim 13, wherein the storage element (3) is integrated in the upstream machine (USM) and/or the downstream machine (DSM), i.e., in the first automatic machine (2, 2', 2") and/or in the second automatic machine (2, 2', 2").
15) System (1) according to claim 13 or 14, wherein the first and/or the second (2, 2', 2") automatic machine comprise a plurality of storage elements (3) integrated therein; in particular, each of the storage elements (3) has a capacity to allow a compensation time of less than 10 minutes.
EP22800774.6A 2021-10-15 2022-10-13 Method for regulating a system for the production and/or the packaging of consumer articles and relative system Pending EP4416564A1 (en)

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PCT/IB2022/059813 WO2023062571A1 (en) 2021-10-15 2022-10-13 Method for regulating a system for the production and/or the packaging of consumer articles and relative system

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