JP2018534931A - Adaptive control method of operation of manufacturing machine-packaging machine group - Google Patents

Abstract

A method of controlling the operation of a group consisting of a cigarette making machine, a cigarette wrapping machine, and a buffer is provided, the operation of the cigarette making machine and the cigarette wrapping machine depending on the filling level of the buffer. The method is to set at least one operating parameter of the group to a starting value, wherein the parameter correlates an operating state of the cigarette maker or cigarette wrapping machine and a filling level of the buffer; Operating the group over a first cycle time based on at least one operating parameter; determining the group comparison efficiency as a ratio of the efficiency of the machine operation over the first cycle time to the efficiency of the packaging machine; Resetting at least one operating parameter to an updated value depending on the determined group comparison efficiency at the end of the first cycle time.
[Selection] Figure 1

Description

  The present invention relates to a system and method for controlling the operation of a group consisting of a cigarette making machine, a cigarette wrapping machine, and a buffer.

  Smoking articles such as cigarettes generally consist of a cigarette making machine (starting from raw materials such as tobacco cut filler, wrapping paper, filter segments, and chipping paper) and a packaging machine (bundle of smoking articles). Manufactured and packaged by a group of highly automated units consisting of, in turn, and packaged in a container such as a hinge lid container.

  In these groups of automated units, a buffer is generally provided between the cigarette making machine and the cigarette wrapping machine. The buffer acts as a reservoir for the formed smoking article to minimize the dependency between the cigarette making machine and the cigarette wrapping machine.

  Some operating parameters of the cigarette making machine, the buffer, and the cigarette wrapping machine need to be preset from the standpoint of specific manufacturing requirements. Whenever one such group is operated to produce cigarettes with different characteristics (eg, different brands or designs of cigarettes), certain operating parameters are set to ensure stable operation of the group. It is necessary to set to a different specific value.

  Cigarette making machines and cigarette wrapping machines are operated at independent variable production rates. In general, cigarette making machines and cigarette wrapping machines are typically operated at different predetermined production rates so that the buffer fill level changes over time.

  When the buffer is full, the cigarette maker needs to be stopped and will only resume when the buffer fill level falls below the first maker threshold (the cigarette maker start limit). To reduce the occurrence of a cigarette maker outage, the cigarette when the buffer fill level exceeds a second maker threshold (a cigarette maker deceleration limit) that is generally lower than the first maker threshold. It has been proposed to reduce the production speed of manufacturing machines. Such deceleration is a preset parameter of the cigarette making machine.

  When the buffer fill level is reduced back to a value below the second manufacturing machine threshold, the production rate of the cigarette manufacturing machine can be increased again. However, in order to limit the frequency at which the cigarette maker switches speeds, the cigarette is only used when the buffer fill level falls below the second maker threshold by a predetermined amount (cigarette maker hysteresis width). It has been proposed to increase the production speed of the manufacturing machine.

  On the other hand, when the buffer becomes empty, the cigarette wrapping machine needs to be stopped and restarted only when the buffer filling level reaches the first wrapping machine threshold (the start limit of the cigarette wrapping machine). To reduce the occurrence of cigarette wrapping machine outages, when the buffer fill level falls below a second wrapping machine threshold (cigarette wrapping machine deceleration limit), which is generally higher than the first wrapping machine threshold, It has further been proposed to reduce the production rate of cigarette wrapping machines. This reduction in cigarette wrapping machine speed is a preset parameter of the cigarette wrapping machine.

  When the buffer filling level increases and returns to a value higher than the second packaging machine threshold, the production rate of the cigarette packaging machine can be increased again. However, in order to limit the frequency with which the cigarette wrapping machine switches the speed, the cigarette wrapping machine only when the buffer filling level exceeds the second manufacturing machine threshold by a predetermined amount (cigarette wrapping machine hysteresis width). It has been proposed to increase the production rate.

  Some cigarettes are excluded whenever the cigarette maker stops. Similarly, some cigarette packages are excluded whenever the cigarette wrapping machine stops. In addition to the conditions specified above, other reasons such as machine failure, lack of one or more starting materials may cause the cigarette making machine or cigarette wrapping machine to be stopped. . Furthermore, some cigarettes, or cigarette packages, or both may be excluded during manufacture if it is found that certain quality requirements are not met. All of these exclusions represent losses, so it would be desirable to limit the outage of cigarette making machines and cigarette wrapping machines.

  In more general terms, it would be desirable to increase the productivity and overall efficiency of the group consisting of cigarette making machines, cigarette wrapping machines, and buffers. In practice, the overall efficiency of one such group is “uptime”, ie the total number of cigarettes actually produced over a given time and the group is always run at design speed over the same time. May be evaluated as a ratio of the number of cigarettes that can theoretically be produced.

  Therefore, the operation of the cigarette maker, cigarette wrapping machine, and the group of buffers placed between the cigarette maker and cigarette wrapping machine is controlled so that the overall efficiency of the group is increased. It would be desirable to provide a way to do this. In addition, one such group of operations increases the total number of production (eg expressed in terms of the total number of cigarettes produced and packaged over a given time) (eg, the number of exclusions in production). It would be desirable to provide a way to control (by reducing). Furthermore, it would be desirable to provide a system that implements one such method.

  According to an aspect of the present invention, there is provided a method for controlling the operation of a group consisting of a cigarette maker, a cigarette wrapping machine, and a buffer, wherein the cigarette maker is upstream of the buffer and the cigarette in the direction of travel. The wrapping machine is downstream of the buffer, and the group is configured such that the operation of the cigarette making machine and the operation of the cigarette wrapping machine depend on the filling level of the buffer. The method includes setting at least one operating parameter of the group to a starting value, wherein the parameter correlates an operating state of the cigarette making machine or cigarette wrapping machine and a filling level of the buffer, and at least Operating the group for a predetermined first cycle time based on one operating parameter. Further, the method determines the operating efficiency of the cigarette maker over the first cycle time, determines the operating efficiency of the cigarette wrapping machine over the first cycle time, and the operating efficiency of the cigarette maker. And determining the group comparison efficiency as a ratio of the operational efficiency of the cigarette wrapping machine. Further, the method includes resetting at least one operating parameter to an updated value depending on the group comparison efficiency at the end of the first cycle time.

  According to a further aspect of the present invention, there is provided a system comprising a first group of cigarette making machines, cigarette wrapping machines, and buffers, wherein the cigarette making machine is upstream of the buffer and the cigarette with respect to the direction of travel. The cigarette wrapping machine is downstream of the buffer, so that the operation of the cigarette making machine and the operation of the cigarette wrapping machine depend on the filling level of the buffer. Further, the system includes a first sensor means for detecting the filling level of the buffer in the first group, the actual production volume of the cigarette maker, and the actual production volume of the cigarette wrapping machine; Of the first group according to the method as set forth above and operatively connected to any one of the cigarette making machines, cigarette wrapping machines, buffers, or any combination thereof within the group of A control unit configured to manage the operation.

  Of course, any feature described with reference to one aspect of the invention is equally applicable to any other aspect of the invention.

  In contrast to the well-known method of operating a group of automated units consisting of a cigarette making machine, a buffer and a cigarette wrapping machine, how various automated units within the group according to the invention can be operated. At least one of the following parameters (i.e., in particular, how the operating conditions of the cigarette making machine and cigarette wrapping machine are affected by the filling level of the buffer) Is adaptively adjusted as a function of measured values of cigarette making machine efficiency and cigarette packaging machine efficiency.

  By managing the operation of one such group with the method according to the invention, the inventors can advantageously increase the overall productivity and efficiency of the group both in terms of overall cigarette production and uptime. I found. In general, unequal full production rates of cigarette making machines and cigarette wrapping machines can advantageously reduce the impact.

  In addition, the inventors may be able to further optimize the method according to the present invention taking into account group planned routine outages (eg, for cleaning purposes), and the resulting group efficiency. It has been found that the obvious changes in do not affect the adaptive control logic underlying the method of the present invention.

  The term “cigarette making machine” is used throughout this specification to refer to an automated cigarette, filter rod, wrapper paper, and chipping paper that are configured to receive and form a plurality of filtered cigarettes from the raw material. Used to refer to a unit. Cigarette making machines can generally operate at full and reduced production rates. Thus, the cigarette maker can be in one of several different operating states (eg, full speed, slowed down, stopped). “Production rate” or “production rate” refers throughout this specification to the number of articles produced in a given period (in the case of cigarette making machines, the number of cigarettes). As an example, production rate or rate is measured and expressed in terms of cigarettes / hour.

  Several manufacturers and models of cigarette making machines will be well known to those skilled in the art. For example, one such automated unit is PROTOOS PM 100 (manufactured by Hauni Machinechinbau AG, Germany).

  The term “cigarette wrapping machine” is used throughout this specification to receive a filtered cigarette and packaging material and to order and package a bundle of filtered cigarettes to form a filtered cigarette pack. Is used to refer to an automated unit configured as follows. Cigarette wrapping machines can generally be operated at full and reduced production rates. Therefore, the cigarette wrapping machine can be in one of several different operating states (eg, full speed, slowed down, stopped). In the case of a cigarette wrapping machine, the production rate or rate generally refers to the number of items manufactured in a given period, ie the number of packs. Each pack contains a predetermined number of cigarettes, for example 20 cigarettes / packs. Therefore, the production rate or rate of a cigarette wrapping machine may conveniently be expressed as the number of cigarettes packed in a given period, so that the production rate of a cigarette wrapping machine can be expressed as a cigarette. It is easier to compare and correlate with the production speed of the machine. Accordingly, in the following, the production rate of a cigarette wrapping machine will also be measured and expressed in terms of cigarette / hour.

  Several manufacturers and models of cigarette wrapping machines will be well known to those skilled in the art. For example, one such automated unit is F550 (manufactured by Focke GmbH (Germany)).

  The term “buffer” is used throughout this specification to refer to an automated unit configured to receive cigarettes formed by a cigarette maker and move them to a cigarette wrapping machine. The

  Several manufacturers and models of buffers will be well known to those skilled in the art. One such automated unit is CAPRICORN (made by ITM (Netherlands)).

  As used herein, one or more “group operating parameters” refers to parameters that set the dependence of the operating state of the cigarette making machine or cigarette wrapping machine on the buffer fill level. In practice, the “group operating parameter” corresponds to a given filling level of a buffer configured to change the operating state of one or both of the cigarette making machine and the cigarette wrapping machine. .

  One such operating parameter is, for example, the cigarette making machine deceleration limit, above which the cigarette making machine production rate is reduced from a full production rate to a reduced production rate. It is.

Other operating parameters for these groups include the following:
“Start limit of the cigarette maker”, that is, the buffer fill level below which the cigarette maker resumes operation after a stop caused by buffer filling.
“Cigarette making machine hysteresis width”, ie, the deceleration limit of the cigarette making machine, below which the production speed of the cigarette making machine is increased from the reduced production speed back to full production speed, The difference between the filling level of the buffer.
“Deceleration limit of cigarette wrapping machine”, ie, the buffer filling level below which the production rate of the cigarette wrapping machine is reduced from the full production rate to the reduced production rate.
“Start limit of cigarette wrapping machine”, ie the filling level of the buffer above which the cigarette wrapping machine resumes operation after a stop caused by the buffer becoming empty.
“Cigarette wrapping machine hysteresis width”, ie, the deceleration limit of the cigarette wrapping machine, and above this, the production speed of the cigarette wrapping machine is increased from the reduced production speed back to full production speed, The difference between the filling level of the buffer. FIG. 1 qualitatively illustrates how these parameters can be related to each other.

The term “operating efficiency of a cigarette maker” is used throughout this specification to refer to the actual and theoretical output of the machine, which is the number of cigarettes actually produced during the scheduled production time. Used to refer to the ratio. The theoretical production is calculated as the product of the scheduled production time and the full production rate of the cigarette maker.

Throughout this specification, the term “cigarette wrapping machine operating efficiency” refers to the actual and theoretical output of a manufacturing machine, which is the number of cigarettes actually packed during the scheduled manufacturing time. Used to refer to the ratio. The theoretical production is calculated as the product of the scheduled production time and the full production rate of the cigarette wrapping machine.

  The method according to the invention is for controlling the operation of a group of automated units consisting of a cigarette maker, a cigarette wrapping machine, and a buffer, with respect to the direction of travel, the cigarette maker is upstream of the buffer. Yes, and the cigarette wrapping machine is downstream of the buffer. One such group is configured according to a predetermined logic such that the operation of the cigarette making machine and the operation of the cigarette wrapping machine depend on the filling level of the buffer. In particular, the operating conditions of the cigarette making machine or the cigarette wrapping machine or both are affected by the filling level of the buffer. As an example, a cigarette making machine or cigarette wrapping machine is typically configured to run at full production speed or to run or stop at reduced production speed when the buffer fill level changes from 0 percent to 100 percent. Is done.

  In the method according to the invention, at least one group of operating parameters, the parameters defining the relationship between the cigarette making machine or cigarette packaging machine operating state and the filling level of the buffer are set to a starting value, and the group is at least 1 Operate over a predetermined first cycle time based on one operating parameter.

  Further, the method determines the operating efficiency of the cigarette maker over the first cycle time, determines the operating efficiency of the cigarette wrapping machine over the first cycle time, and the operating efficiency of the cigarette maker. And determining the group comparison efficiency as a ratio of the operational efficiency of the cigarette wrapping machine. At the end of the first cycle time, at least one parameter is reset to an updated value depending on the determined group comparison efficiency.

  Advantageously, the actual production volume of the cigarette making machine and the cigarette making machine efficiency and the cigarette wrapping machine efficiency can be determined at any given time during the first cycle time. Preferably, the actual production volume of the cigarette wrapping machine is continuously monitored. Alternatively, the actual production volume of the cigarette wrapping machine may be detected at predetermined intervals during the first cycle time, so that the cigarette making machine at a predetermined moment during the first cycle time. Only individual values of the efficiency of the cigarette and the efficiency of the cigarette wrapping machine may be determined. At least one parameter is reset to an updated value based on the group comparison efficiency as determined at the end of the first cycle time, so that the actual production of the cigarette making machine and the cigarette wrapping machine is Detected at least at the end of the first cycle time.

  The at least one parameter is reset to an updated value depending on the group comparison efficiency determined at the end of the first cycle time.

  Thus, in the method according to the invention, the quality and the interrelationship of operation between the cigarette maker and the buffer, or between the cigarette wrapping machine and the buffer, or both ranges are revised during the operation of the group. Is done. Among them, advantageously, the group is initially operated with at least one parameter set at a starting value specifically selected for a given brand or manufacturer's cigarette, but thus the raw material And for a given combination of manufacturing requirements, the same parameters are adaptively adjusted in terms of changes in the efficiency of the automated units involved in the manufacturing process.

  At least one operating parameter includes: a cigarette maker start limit, a cigarette maker deceleration limit, a cigarette maker hysteresis width, a cigarette wrap machine start limit, a cigarette wrap machine deceleration limit, a cigarette wrapping machine It is preferably selected from the group consisting of hysteresis widths. The inventor uses one of these parameters to clearly set the correlation between the operating state of the cigarette making machine or cigarette wrapping machine and the filling level of the buffer, according to the logic underlying the present invention. By adaptively adjusting the above, we observed that the productivity and efficiency of the group as a whole easily increased.

  The step of resetting the value of the at least one operating parameter preferably includes determining a corrected value of the at least one operating parameter as a function of the group comparison efficiency at the end of the first cycle time.

  In some embodiments, if the corrected value of the at least one parameter is within a range from the lower boundary value of the at least one parameter to the upper boundary value of the at least one parameter, the at least one operating parameter is corrected Reset to the specified value. Otherwise, if the corrected value of at least one parameter is less than the lower boundary value of at least one parameter or greater than the upper boundary value of at least one parameter, at least one operating parameter is taken as the starting value Reset it.

  In other embodiments, if the corrected value of the at least one parameter is from the lower boundary value of the at least one parameter to the upper boundary value of the at least one parameter, the at least one operating parameter is set to the corrected value. Reset it. If the corrected value of the at least one parameter is less than the lower boundary value of the at least one parameter, reset the at least one operating parameter to the lower boundary value of the at least one parameter. If the corrected value of the at least one parameter is greater than the upper boundary value of the at least one parameter, reset the at least one operating parameter to the upper boundary value of the at least one parameter.

  In this way, it can advantageously be checked that at least one operating parameter falls within an acceptable range. This is not only due to inherent constraints on the nature of the group (for example, the buffer fill level can only be between 0 percent and 100 percent), but there is a certain relationship between the various operating parameters. Also related to the fact that is preferred. As an example, the deceleration limit of the cigarette making machine is preferably lower than the start limit of the cigarette making machine. In addition, advantageously, the boundary values can be optimized so that the implementation of the method according to the invention obtains the most stable increase in production.

  Determining the corrected value of the at least one operating parameter may include determining the baseline value of the at least one operating parameter by a factor substantially equal to the group comparison efficiency at the end of the first cycle time, or the reciprocal thereof. Preferably including multiplication by.

  The start limit of the cigarette maker defines a buffer fill level below which the cigarette machine operation is resumed after an outage caused by buffer filling. When the full production rate of the cigarette making machine is greater than the full production rate of the cigarette wrapping machine (ie, the bottleneck area is close to 100% buffer filling level), the efficiency of the cigarette making machine remains constant, and If cigarette wrapping efficiency increases, the stoppage of the cigarette making machine caused by the full buffer will be reduced. When the full production rate of the cigarette wrapping machine is greater than the full production rate of the cigarette maker (ie, the bottleneck area is close to 0% buffer filling level), the efficiency of the cigarette maker remains constant, and Similar behavior is expected when cigarette packaging efficiency increases.

However, in the latter case, the occurrence of a cigarette machine stoppage is reduced to a slightly greater extent. In practice, the amount of buffer contents that need to be consumed by the cigarette wrapping machine before the cigarette maker can start again can be reduced. Thus, the starting limit of a cigarette making machine can be considered as being directly proportional to the efficiency of the packaging machine. At the same time, the starting limit of a cigarette maker can be viewed as being inversely proportional to the efficiency of the cigarette maker. So we can think of it as follows:

  The cigarette making machine deceleration limit defines a buffer fill level above which the cigarette making machine production rate is reduced from a full production rate to a reduced production rate. When the full production rate of the cigarette making machine is greater than the full production rate of the cigarette wrapping machine (ie, the bottleneck area is close to 100% buffer filling level), the efficiency of the cigarette making machine remains constant, and As the efficiency of cigarette wrapping increases, the wrapping machine consumes more inherently, reducing the cigarette machine stoppage that occurs when the buffer is full. On the other hand, if the full production rate of the cigarette wrapping machine is greater than the full production rate of the cigarette maker (ie, the bottleneck area is close to 0% buffer filling level), the efficiency of the cigarette maker remains constant. However, if the efficiency of cigarette wrapping increases, the frequency at which the buffer fills will be reduced to a much greater extent. Thus, the filling level range in which the cigarette making machine operates at a reduced speed may be reduced. This results in an additional filling level range that allows the cigarette maker to operate at full production rates, which is expected to result in increased production.

Therefore, it can be considered that the deceleration limit of the cigarette making machine is directly proportional to the efficiency of the packaging machine. At the same time, the deceleration limit of the cigarette making machine can be considered to be inversely proportional to the efficiency of the cigarette making machine. So we can think of it as follows:

  The cigarette making machine hysteresis width is the buffer filling level above which the cigarette making machine production rate is reduced from the full production rate to the reduced production rate (ie, the cigarette making machine deceleration limit), and Below this, the production rate of the cigarette making machine defines a difference between the buffer filling level that is increased to return from the reduced production rate to the full production rate. When the full production rate of the cigarette making machine is greater than the full production rate of the cigarette wrapping machine (ie, the bottleneck area is close to 100% buffer filling level), the efficiency of the cigarette making machine remains constant, and As the efficiency of cigarette wrapping machines increases, the likelihood that the cigarette making machine will need to be shut down due to a full buffer will be slightly increased. However, if the full production rate of the cigarette wrapping machine is greater than the full production rate of the cigarette maker (ie, the bottleneck area is close to 0% buffer filling level), the efficiency of the cigarette maker remains the same. And if the efficiency of the cigarette wrapping machine increases, the possibility that the cigarette wrapping machine stops due to the empty buffer is increased. Thus, under these circumstances, the cigarette maker hysteresis width may be reduced in terms of limiting the impact of creating bottlenecks.

Thus, the cigarette making machine hysteresis width can be considered to be inversely proportional to the efficiency of the cigarette wrapping machine. At the same time, the cigarette making machine hysteresis width can be considered to be directly proportional to the efficiency of the cigarette making machine. So we can think of it as follows:

  The starting limit of the cigarette wrapping machine defines the filling level of the buffer above which the cigarette wrapping machine is resumed after a stop caused by the buffer being emptied. When the full production rate of the cigarette making machine is greater than the full production rate of the cigarette wrapping machine (ie, the bottleneck area is close to the buffer fill level of 100 percent), the efficiency of the cigarette wrapping machine remains constant, and When the efficiency of the cigarette making machine increases, the stoppage of the cigarette wrapping machine caused by the emptying of the buffer will be reduced. Thus, to enhance manufacturing, the starting limit of the cigarette wrapping machine can be reduced so that the cigarette wrapping machine has a wider range of buffer fill level values that are effectively productive. However, if the full production rate of the cigarette making machine is greater than the full production rate of the cigarette wrapping machine (ie, the bottleneck area is close to 100% buffer filling level), the efficiency of the cigarette wrapping machine remains constant. And when the efficiency of the cigarette making machine increases, the stoppage of the cigarette wrapping machine caused by the emptying of the buffer is reduced. Therefore, the starting limit of a cigarette wrapping machine should be lowered by a smaller amount. Thus, the starting limit of a cigarette wrapping machine can be considered to be inversely proportional to the efficiency of the cigarette making machine.

If the cigarette maker's full production rate is greater than the cigarette wrapping machine's full production rate, the efficiency of the cigarette maker remains constant and the packaging machine's efficiency increases, the buffer may be empty. Will increase. Therefore, the starting limit of cigarette wrapping machines should be increased to improve productivity. On the other hand, if the cigarette wrapping machine's full production rate is greater than the cigarette maker's full production rate, the packaging machine's efficiency will increase while the cigarette maker's efficiency will remain the same. Conditions will occur much more frequently than full buffer conditions. Thus, in one such case, the starting limit of the cigarette wrapping machine should be increased to a greater extent. Thus, the starting limit of a cigarette wrapping machine can be considered to be directly proportional to the efficiency of the cigarette wrapping machine. So we can think of it as follows:

  The deceleration limit of the cigarette wrapping machine defines a buffer filling level below which the cigarette wrapping machine production rate is reduced from a full production rate to a reduced production rate. If the full production rate of the cigarette making machine is greater than the full production rate of the cigarette wrapping machine, the efficiency of the wrapping machine increases while the efficiency of the cigarette maker remains the same, the cigarette wrapping machine In order to manufacture more, the incidence of cigarette wrapping machine increases. Under these circumstances, the deceleration limit of the cigarette wrapping machine can be advantageously increased. On the other hand, if the full production rate of the cigarette wrapping machine is greater than the full production rate of the cigarette maker, the efficiency of the wrapping machine increases while the efficiency of the cigarette maker remains the same, and the buffer is empty. The deceleration limit of a cigarette wrapping machine should be much higher because it is more likely to become. Therefore, the deceleration limit of the cigarette wrapping machine can be regarded as being directly proportional to the efficiency of the cigarette wrapping machine.

If the cigarette making machine's full production rate is greater than the cigarette wrapping machine's full production rate, the cigarette making machine's efficiency increases while the cigarette wrapping machine's efficiency remains the same, and the buffer is empty. Is unlikely. Therefore, under such circumstances, the deceleration limit of the cigarette wrapping machine can be lowered. On the other hand, if the full production speed of the cigarette wrapping machine is greater than the full production speed of the cigarette maker, the bottleneck area is close to the buffer filling level of 0%, so the reduction in the cigarette wrapping machine's deceleration limit is only small. Should not be so significant. So we can think of it as follows:

  The cigarette wrapping machine hysteresis width is below the buffer filling level (i.e., the cigarette wrapping machine deceleration limit) at which the cigarette wrapping machine production rate is reduced from full production rate to reduced production rate, and Above this, the production rate of the cigarette wrapping machine defines the difference between the increased filling level of the buffer so that it returns from the reduced production rate to the full production rate. If the full production rate of the cigarette making machine is greater than the full production rate of the cigarette wrapping machine, the buffer fill level will be close to 100 for most of the manufacturing time. While the efficiency of a cigarette maker increases, if the efficiency of the cigarette wrapping machine remains constant, the number of stops of the cigarette wrapping machine will increase. On the other hand, if the full production rate of the cigarette wrapping machine is greater than the full production rate of the cigarette maker, the increased efficiency of the wrapping machine results in a significant number of stoppages of the wrapping machine. To take action against this effect, the cigarette wrapping machine hysteresis width can be increased so that the impact of stopping the cigarette wrapping machine is reduced. Thus, the cigarette wrapping machine hysteresis width can be considered to be directly proportional to the efficiency of the cigarette wrapping machine.

If the cigarette making machine's full production rate is greater than the cigarette wrapping machine's full production rate, the cigarette wrapping machine efficiency remains the same, and if the cigarette making machine efficiency increases, the buffer is full The cigarette making machine will stop more frequently. Under these conditions, the cigarette wrapping machine hysteresis width can be reduced, so that the wrapping machine can be operated at full production speed for as long as possible. Similar behavior can be observed when the full production rate of the cigarette wrapping machine is greater than the full production rate of the cigarette maker. Accordingly, the cigarette wrapping machine hysteresis width can be considered to be inversely proportional to the efficiency of the cigarette making machine. So we can think of it as follows:

  In view of these points, the inventors advantageously multiply the baseline value of at least one operating parameter by a factor substantially equal to the group comparison efficiency at the end of the first cycle time, or It has been found that the corrected value of at least one operating parameter can be determined by multiplying by its reciprocal. Thus, a substantially linear relationship is always established between at least one parameter and the ratio of the cigarette wrapping machine efficiency to the cigarette making machine efficiency, or the reciprocal thereof.

  The baseline value for at least one parameter is preferably determined as the value of at least one parameter, which results under conditions such that the efficiency of the cigarette making machine is substantially equal to the efficiency of the cigarette wrapping machine. As a group brings optimized productivity. This can be achieved, for example, by simulating the behavior of the group, so that the effect on the productivity of the various values of the baseline value for at least one parameter is favored without having to operate the group effectively. It can be evaluated.

  During the operation of the group, several further cycles may follow the first cycle. The actual production volume of the cigarette making machine, the actual production volume of the cigarette wrapping machine, and the operating efficiency of the cigarette making machine are preferably continuously monitored during further cycle times. Thus, advantageously, the current value of the cigarette making machine efficiency, or the packaging machine efficiency, or both, can be determined at any given time during any further cycle time. However, the output of the cigarette making machine and the output of the cigarette wrapping machine may be alternately measured at predetermined intervals during any further cycle time. In some preferred embodiments, the method operates the group for an additional cycle time based on the updated at least one operating parameter, and determines the operating efficiency of the cigarette maker for the additional cycle time; Determining the cigarette wrapping machine operating efficiency over an additional cycle time and determining the group comparison efficiency as the ratio of the cigarette maker operating efficiency to the cigarette wrapping machine operating efficiency at the end of the further cycle time And including. If the group comparison efficiency at the end of the further cycle time differs from the group comparison efficiency at the start of the further cycle time by at least 5 percent, the at least one operating parameter is further updated depending on the group comparison efficiency at the end of the further cycle time Reset to the specified value. In another case, if the group comparison efficiency at the end of the further cycle time differs by less than 5 percent from the group comparison efficiency at the start of the further cycle time, at least one operating parameter is maintained unchanged.

  Advantageously, a check is performed to see if the behavior of the automated units in the group changes significantly between the start and end of further cycles. This is assessed through the determination of any change in group comparison efficiency between the start and end of further cycles. If the behavior of any one of the automated units in the group remains substantially unchanged, at least one parameter need not actually be reset. On the other hand, if a relevant change occurs in the behavior of any one of the automated units in the group, it is preferable to reset at least one parameter to an updated value that takes into account the change.

  The step of resetting the at least one operating parameter may include measuring the measured / determined operating efficiency of the cigarette maker and the measured / determined operating efficiency of the cigarette wrapping machine at the end of a further cycle time. Preferably, the method further includes determining a further updated value of the at least one operating parameter based on the ratio value. If the updated value of the at least one parameter is in a range from the predetermined lower boundary value of the at least one parameter to the predetermined upper boundary value of the at least one parameter, the updated value determined for the at least one parameter is updated. Set the value again. In another case, if the updated value of at least one parameter is less than a predetermined lower boundary value of at least one parameter or greater than a predetermined upper boundary value of at least one parameter, at least one operational parameter Is maintained unchanged.

  Alternatively, resetting the at least one operating parameter may include determining a further updated value of the at least one operating parameter based on the value of the group comparison efficiency at the end of the further cycle time. Good. If the further updated value of the at least one parameter is within the range from the lower boundary value of the at least one parameter to the upper boundary value of the at least one parameter, the at least one operating parameter is reset to the further updated value. Is set. If the further updated value of the at least one parameter is less than the lower boundary value of the at least one parameter, the at least one operating parameter is reset to the lower boundary value of the at least one parameter. If the further updated value of the at least one parameter is greater than the upper boundary value of the at least one parameter, the at least one operating parameter is reset to the upper boundary value of the at least one parameter.

  Thus, the check that further updated values fall within an acceptable range is repeated at the end of each further cycle. This is advantageous in that it ensures the stability of the operation of the group being manufactured.

  In an alternative embodiment, the method operates the group for a predetermined additional cycle time based on the adjusted at least one operating parameter, and determines the operating efficiency of the cigarette maker for the additional cycle time. Determining the operating efficiency of the cigarette wrapping machine over an additional cycle time and determining the group comparison efficiency as the ratio of the operating efficiency of the cigarette maker and the operating efficiency of the cigarette wrapping machine at the end of the further cycle time Including.

  If the cigarette maker operating efficiency at the end of the further cycle time is less than the maker baseline efficiency, the average maker baseline efficiency during the further cycle time is assumed to be the current value of the cigarette maker operating efficiency Is done. In other cases, if the operating efficiency of the cigarette maker at the end of the further cycle time is at least as great as the baseline efficiency of the maker, the operating efficiency of the cigarette maker at the end of the further cycle time is It is assumed to be the current value of the operating efficiency of the manufacturing machine.

  If the cigarette wrapping machine operating efficiency at the end of the further cycle time is less than the wrapping machine baseline efficiency, the average wrapping machine baseline efficiency during the further cycle time is assumed to be the current value of the cigarette wrapping machine operating efficiency Is done. In other cases, if the cigarette wrapping machine operating efficiency at the end of the second cycle is at least as great as the manufacturing machine baseline efficiency, the cigarette wrapping machine operating efficiency at the end of the second cycle is It is assumed to be the current value of the operating efficiency of the cigarette wrapping machine.

  In these alternative embodiments, the method further includes determining the current group comparison efficiency as a ratio of the current value of the cigarette making machine operating efficiency to the current value of the cigarette wrapping machine operating efficiency. Then, if the current group comparison efficiency is at least 5 percent different from the group comparison efficiency from the group comparison efficiency at the start of further cycle time, at least one operating parameter is further updated depending on the current group comparison efficiency. The value is reset. In another case, if the current group comparison efficiency differs from the group comparison efficiency from the group comparison efficiency at the start of further cycle time by less than 5 percent, at least one operating parameter is maintained unchanged.

  By considering the average value of the efficiency of the automated units in the group, it is advantageous not to be due to the buffer fill level reaching 100 percent or 0 percent, but other such as planned production interruptions. It is possible to reduce the possibility of confusion that may be caused by a stoppage of the cigarette maker or cigarette wrapping machine caused by the reason.

  Preferably, the step of resetting the value of the at least one operating parameter includes determining a further updated value of the at least one operating parameter based on the current group comparison efficiency.

  In some embodiments, if the further updated value of the at least one parameter is within the range from the lower boundary value of the at least one parameter to the upper boundary value of the at least one parameter, the at least one operating parameter is It is reset to a further updated value. In another case, if the further updated value of the at least one parameter is less than the lower boundary value of the at least one parameter or greater than the upper boundary value of the at least one parameter, the at least one operating parameter is not changed. Maintained without.

  In an alternative embodiment, if the further updated value of the at least one parameter is within the range from the lower boundary value of the at least one parameter to the upper boundary value of the at least one parameter, the at least one operating parameter is further It is reset to the updated value. In another case, if the further updated value of the at least one parameter is less than the lower boundary value of the at least one parameter, the at least one operating parameter is reset to the lower boundary value of the at least one parameter. Finally, if the further updated value of the at least one parameter is greater than the upper boundary value of the at least one parameter, the at least one operating parameter is reset to the upper boundary value of the at least one parameter.

  A system for carrying out the method according to the invention comprising a first group of cigarette making machines, cigarette wrapping machines, and buffers, with respect to the direction of travel, the cigarette making machine is upstream of the buffer and the cigarettes The packaging machine is downstream of the buffer. The operation of the cigarette making machine and the operation of the cigarette wrapping machine depend on the filling level of the buffer. The system further includes, in the first group, first sensor means for detecting the filling level of the buffer and measuring the production of the cigarette making machine and the production of the cigarette wrapping machine. Further, the system is operably connected to any one of the cigarette making machines, cigarette wrapping machines, buffers, or any combination thereof in the first group and according to the method set forth above. A control unit configured to manage the operation of the first group.

  The control unit is essentially configured to implement the control logic according to the method described above. Therefore, the control unit not only correlates the operating state of the cigarette maker and cigarette wrapping machine with the filling level of the buffer, but also the cigarette maker, the cigarette wrapping machine, or both. It also ensures that the nature and quality of these interrelationships are verified and changed over time to accommodate possible changes in efficiency.

  In some embodiments, one such system comprises a further group of cigarette making machines, cigarette wrapping machines, and buffers, with respect to the direction of travel, the cigarette making machine is upstream of the buffer and the cigarette wrapping. The machine is downstream of the buffer, so that the operation of the cigarette making machine and the operation of the cigarette wrapping machine depend on the filling level of the buffer. Furthermore, the system comprises a second sensor means for detecting the filling level of the buffer and measuring the output of the cigarette maker and the cigarette wrapping machine in the second group. The control unit is further operatively connected to any one of the cigarette maker, cigarette wrapping machine, buffer, or any combination thereof in the second group and according to the method set forth above Configured to manage the operations of the first group and further groups.

  This is because in systems that run two or more such groups of automated units in parallel, the same logic can be implemented in various groups based on observation of the behavior of all automated units in the system. It is advantageous in that it can be done. Thus, advantageously, the overall productivity of the system can be increased.

  The invention will be further described, by way of example only, with reference to the accompanying drawing figures.

FIG. 1 shows parameters that define how the operation of a cigarette maker and cigarette wrapping machine correlates with the filling level of a buffer placed between the cigarette maker and the cigarette wrapping machine. Figure 2 illustrates a qualitative example of FIG. 2 is a flowchart illustrating the steps of the method according to the invention. FIG. 3 is a flowchart illustrating the steps of a preferred embodiment of the method according to the invention. FIG. 4 is a flow chart illustrating the steps of a further preferred embodiment of the method according to the invention.

  FIG. 1 shows several operating parameters of the group consisting of a cigarette making machine, a cigarette wrapping machine, and a buffer. The parameter correlates the operating state of the cigarette making machine and cigarette wrapping machine with the filling level of the buffer. These include the start limit of the cigarette maker, the deceleration limit of the cigarette maker, the hysteresis width of the cigarette maker, the start limit of the cigarette wrapping machine, the speed limit of the cigarette wrapping machine, and the hysteresis width of the cigarette wrapping machine. Is included.

  PROTOOS PM 100 as a cigarette maker (Hauni Maschinenbau AG (Germany)), F550 as a cigarette wrapping machine (Focke GmbH (Germany)), and CAPRICORN (ITM (Netherlands)) as a buffer, One such group consisting of is installed. The full production rate of PROTOS PM 100 is 10,000 cigarettes / minute. The full production rate of the F550 is 500 packs / minute, each pack containing 20 cigarettes (also corresponding to the processing of 10,000 cigarettes per minute). The effective capacity of CAPRICORN is 125,000 cigarettes, and the upstream and downstream speeds are 10,000 cigarettes / minute.

表１−グループの動作パラメータに対するベースライン値 Baseline values for the listed operating parameters are determined based on the results of simulations performed under the assumption that the operating efficiency of the cigarette making machine is substantially equal to the operating efficiency of the cigarette wrapping machine. The baseline value is selected as the value of the operating parameter that results in optimized group productivity. Table 1 below lists the baseline values determined from the simulation.

Table 1-Baseline values for group operating parameters

表２−グループの動作パラメータに対するベースライン値 Boundary values are set for operating parameters to ensure stable operation of the group. Table 2 below lists the boundary values.

Table 2-Baseline values for group operating parameters

  FIG. 2 is a flow chart illustrating a first embodiment of the method according to the invention.

  The above group operating parameters are set to their respective starting values and the group is operated for a first cycle time of 1 hour. During this time, the operation of the group is monitored in order to determine the cigarette making machine operating efficiency, the cigarette wrapping machine operating efficiency, and its ratio taken as group comparison efficiency.

  After 1 hour, the corrected value of the operating parameter is determined as a function of the group comparison efficiency. Thus, the updated value of the cigarette maker start limit is calculated by multiplying the associated baseline value by the determined value of the group comparison efficiency (see Equation 1). Similar calculations are made for the cigarette making machine deceleration limit, the cigarette wrapping machine start limit, the cigarette wrapping machine deceleration limit, and the cigarette wrapping machine hysteresis width (see Equations 2, 4, 5 and 6). ) The updated value of the cigarette machine hysteresis width is calculated by multiplying the associated baseline value by the inverse of the determined value of the group comparison efficiency.

  The operating parameters are reset to these updated values. The group is operated for an additional cycle time of 1 hour. At the end of the further cycle time, the group comparison efficiency is again determined. If the group comparison efficiency changes by at least 5 percent between the start and end of further cycle time, a new updated value for the operating parameter is calculated as set above, and the operating parameter is updated accordingly. The value is reset. Otherwise, if the group comparison efficiency changes by less than 5 percent between the start and end of further cycle time, the operating parameters are left unchanged.

  Compared to the same group operated without adaptive control, an approximately 0.25 percent increase in uptime was found when operating the group by the method as illustrated in FIG.

  FIG. 3 illustrates a second embodiment of the method according to the invention. Here, only the parts different from the embodiment of FIG.

  The method as illustrated by the flowchart of FIG. 3 differs from the above-described embodiment in that a further check is provided immediately after the updated value of the operating parameter is determined. In practice, the updated value of each one of the operating parameters is compared with the corresponding boundary value. If the updated value is contained within the boundary value, this is used to reset the value of the operating parameter. Otherwise, if the updated value exceeds the upper boundary value, the upper boundary value is used to reset the value of the operating parameter. Finally, if the updated value falls below the lower boundary value, the lower boundary value is used to reset the value of the operating parameter.

  Compared to the same group operated without adaptive control, an increase of about 0.6% to 0.8% in uptime was found when operating the group by the method as illustrated in FIG. .

  FIG. 4 illustrates a third embodiment of the method according to the invention. Here, only the parts different from the embodiment of FIG.

  The method as illustrated by the flowchart of FIG. 4 differs from the above-described embodiment in that a further check is provided immediately after the determination of the updated value for the operating parameter. In practice, the current value of cigarette making machine efficiency and cigarette packaging efficiency is compared to a baseline value of efficiency (eg, 30 percent). If the current value of cigarette maker efficiency and cigarette wrapping efficiency is at least equal to the relevant baseline value, then the cigarette maker efficiency and cigarette will be used to check for changes in efficiency during the subsequent cycle time. The current value of packaging efficiency is used. Otherwise, if the current value of cigarette making machine efficiency and cigarette packaging efficiency is lower than the relevant baseline value, the average value of efficiency during the second cycle time for subsequent efficiency change checks Is used.

  Compared to the same group operated without adaptive control, an up to about 0.9 percent increase in uptime was found when operating the group by the method as illustrated in FIG. This can lead to an increase in production of more than 385,000 cigarettes during a three day production period.

Claims (13)

A cigarette making machine, a cigarette wrapping machine, and a method for controlling the operation of a group comprising a buffer, wherein the cigarette making machine is upstream of the buffer with respect to the direction of movement, and the cigarette wrapping machine is Downstream of the buffer, the group is configured such that operation of the cigarette making machine and operation of the cigarette wrapping machine depend on the filling level of the buffer;
Said method comprises
Setting at least one operating parameter of the group to a starting value, wherein the parameter correlates an operating state of the cigarette maker or cigarette wrapping machine and the filling level of the buffer; And
Operating the group for a predetermined first cycle time based on the at least one operating parameter;
Determining the operating efficiency of the cigarette maker over the first cycle time;
Determining the operating efficiency of the cigarette wrapping machine over the first cycle time;
Determining a group comparison efficiency as a ratio of the operational efficiency of the cigarette maker and the operational efficiency of the cigarette wrapping machine;
Resetting the at least one operating parameter to an updated value depending on the group comparison efficiency at the end of the first cycle time.   The at least one operating parameter includes a start limit of the cigarette maker, a deceleration limit of the cigarette maker, a hysteresis width of the cigarette maker, a start limit of the cigarette wrapping machine, a deceleration limit of the cigarette wrapping machine, and the cigarette packaging. The method of claim 1, wherein the method is selected from the group consisting of a machine hysteresis width. Re-setting the value of the at least one operating parameter;
Determining a corrected value of the at least one operating parameter as a function of the group comparison efficiency at the end of the first cycle time;
If the corrected value of the at least one parameter is within a range from a lower boundary value of the at least one parameter to an upper boundary value of the at least one parameter, the at least one operating parameter is corrected. Resetting the value to
Starting the at least one operating parameter if the corrected value of the at least one parameter is less than the lower boundary value of the at least one parameter or greater than the upper boundary value of the at least one parameter; 3. A method according to claim 1 or 2, comprising resetting to a value. Re-setting the value of the at least one operating parameter;
Determining a corrected value of the at least one operating parameter as a function of the group comparison efficiency at the end of the first cycle time;
If the corrected value of the at least one parameter is from a lower boundary value of the at least one parameter to an upper boundary value of the at least one parameter, the at least one operating parameter is set to the corrected value. Resetting,
Resetting the at least one operating parameter to the lower boundary value of the at least one parameter if the corrected value of the at least one parameter is less than the lower boundary value of the at least one parameter;
Resetting the at least one operating parameter to the upper boundary value of the at least one parameter if the corrected value of the at least one parameter is greater than the upper boundary value of the at least one parameter; The method according to claim 1, comprising:   The step of determining a corrected value of the at least one operating parameter has a baseline value of the at least one operating parameter substantially equal to the group comparison efficiency at the end of the first cycle time; 5. A method according to claim 3 or 4, comprising multiplying by a factor or by its reciprocal. Operating the group for a further cycle time based on the updated at least one operating parameter;
Determining the operating efficiency of the cigarette maker over the further cycle time;
Determining the operating efficiency of the cigarette wrapping machine over the further cycle time;
Determining a group comparison efficiency as the ratio of the operating efficiency of the cigarette maker and the operating efficiency of the cigarette wrapping machine at the end of the further cycle time;
If the group comparison efficiency at the end of the further cycle time differs from the group comparison efficiency at the start of the further cycle time by at least 5 percent, the at least one operating parameter is determined at the end of the further cycle time. Resetting to further updated values depending on the group comparison efficiency;
Maintaining the at least one operating parameter unchanged if the group comparison efficiency at the end of the further cycle time differs by less than 5 percent from the group comparison efficiency at the start of the further cycle time; The method according to claim 1, comprising: Operating the group for a predetermined further cycle time based on the adjusted at least one operating parameter;
Determining the operating efficiency of the cigarette maker over the further cycle time;
Determining the operating efficiency of the cigarette wrapping machine over the further cycle time;
Determining a group comparison efficiency as the ratio of the operating efficiency of the cigarette maker and the operating efficiency of the cigarette wrapping machine at the end of the further cycle time;
If the operating efficiency of the cigarette maker at the end of the further cycle time is less than the maker baseline efficiency, the average maker efficiency during the further cycle time is less than the operating efficiency of the cigarette maker. Assuming current value,
The operating efficiency of the cigarette maker at the end of the further cycle time if the operating efficiency of the cigarette maker at the end of the further cycle time is at least as great as the baseline efficiency of the machine Is the current value of the operating efficiency of the cigarette making machine;
If the operating efficiency of the cigarette wrapping machine at the end of the further cycle time is less than the wrapping machine baseline efficiency, the average wrapping machine efficiency during the further cycle time is the operating efficiency of the cigarette wrapping machine. Assuming the current value of
If the operational efficiency of the cigarette wrapping machine at the end of the second cycle is at least as great as the baseline efficiency of the manufacturing machine, the operation of the cigarette wrapping machine at the end of the second cycle. Assuming efficiency is the current value of the operating efficiency of the cigarette wrapping machine;
Determining a current group comparison efficiency as a ratio of the current value of the operating efficiency of the cigarette making machine to the current value of the operating efficiency of the cigarette wrapping machine;
after that,
If the current group comparison efficiency differs from the group comparison efficiency from the group comparison efficiency at the start of the further cycle time by at least 5 percent, the at least one operating parameter depends on the current group comparison efficiency Reset to a more updated value,
Maintaining the at least one operating parameter unchanged if the current group comparison efficiency differs from the group comparison efficiency from the group comparison efficiency at the start of the further cycle time by less than 5 percent; 6. The method according to any one of claims 1 to 5, comprising: Re-setting the at least one operating parameter;
Based on the value of the ratio of the measured / determined operating efficiency of the cigarette maker to the measured / determined operating efficiency of the cigarette wrapping machine at the end of the further cycle time, Determining a further updated value of at least one operating parameter;
Determining the at least one operating parameter if the updated value of the at least one parameter is from a predetermined lower boundary value of the at least one parameter to a predetermined upper boundary value of the at least one parameter; Resetting the updated value to
If the updated value of the at least one parameter is less than the predetermined lower boundary value of the at least one parameter, or greater than the predetermined upper boundary value of the at least one parameter, the at least one And maintaining the operating parameters unchanged. Re-setting the at least one operating parameter;
Determining a further updated value of the at least one operating parameter based on the value of the group comparison efficiency at the end of the further cycle time;
If the further updated value of the at least one parameter is within a range from a lower boundary value of the at least one parameter to an upper boundary value of the at least one parameter, the at least one operating parameter is Reset it to the updated value,
Resetting the at least one operating parameter to the lower boundary value of the at least one parameter if the further updated value of the at least one parameter is less than the lower boundary value of the at least one parameter; ,
Resetting the at least one operating parameter to the upper boundary value of the at least one parameter if the further updated value of the at least one parameter is greater than the upper boundary value of the at least one parameter; The method of claim 6, comprising: Re-setting the at least one operating parameter;
Determining a further updated value of the at least one operating parameter based on the current group comparison efficiency;
If the further updated value of the at least one parameter is within a range from a lower boundary value of the at least one parameter to an upper boundary value of the at least one parameter, the at least one operating parameter is Reset it to the updated value,
If the further updated value of the at least one parameter is less than the lower boundary value of the at least one parameter or greater than the upper boundary value of the at least one parameter, the at least one operating parameter is Maintaining the same without changing. Re-setting the at least one operating parameter;
Determining a further updated value of the at least one operating parameter based on the current group comparison efficiency;
If the further updated value of the at least one parameter is within a range from a lower boundary value of the at least one parameter to an upper boundary value of the at least one parameter, the at least one operating parameter is Reset it to the updated value,
Resetting the at least one operating parameter to the lower boundary value of the at least one parameter if the further updated value of the at least one parameter is less than the lower boundary value of the at least one parameter; ,
Resetting the at least one operating parameter to the upper boundary value of the at least one parameter if the further updated value of the at least one parameter is greater than the upper boundary value of the at least one parameter; The method of claim 7, comprising: A system,
A first group comprising a cigarette making machine, a cigarette wrapping machine, and a buffer, wherein the cigarette making machine is upstream of the buffer and the cigarette wrapping machine is downstream of the buffer with respect to a moving direction A first group in which the operation of the cigarette making machine and the operation of the cigarette wrapping machine depend on the filling level of the buffer;
First sensor means for detecting a filling level of the buffer in the first group and measuring a production amount of the cigarette maker and a production amount of the cigarette wrapping machine;
12. Operatively connected to any one of the cigarette making machine, the cigarette wrapping machine, the buffer, or any combination thereof in the first group, and any one of claims 1-11. A control unit configured to manage the operation of the first group according to the method defined in paragraph 1. A further group comprising a cigarette making machine, a cigarette wrapping machine, and a buffer, with respect to the direction of travel, the cigarette making machine is upstream of the buffer and the cigarette wrapping machine is downstream of the buffer A further group in which the operation of the cigarette making machine and the operation of the cigarette wrapping machine depend on the filling level of the buffer, so that
A second sensor means for detecting a filling level of the buffer in a second group and measuring the production amount of the cigarette maker and the production amount of the cigarette wrapping machine,
The control unit is further operably connected to any one of the cigarette making machine, the cigarette wrapping machine, the buffer, or any combination thereof in the second group, and 13. The system of claim 12, configured to manage the operation of the first group and the further group according to the method defined in any one of 1-11.

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