KR20180075491A - MANUFACTURING MACHINE - How to adaptively control the operation of a packer group - Google Patents

Abstract

There is provided a method of controlling the operation of a group including a cigarette maker, a cigarette packer and a buffer, and controlling the operation of the cigarette maker and the cigarette packer according to the filling level of the buffer. The method comprising: setting at least one parameter of the group correlating the cigarette maker or cigarette packer with the filling level of the buffer to a starting value; Operating the group for a first cycle time based on at least one operating parameter; Determining a group comparison efficiency as a ratio between the machine operating efficiency and the packer operating efficiency during the first cycle time; And resetting at least one operating parameter to an updated value according to the determined group comparison efficiency at a first cycle time end.

Description

MANUFACTURING MACHINE - How to adaptively control the operation of a packer group

The present invention relates to a system and method for controlling the operation of a group comprising a cigarette maker, a cigarette packer and a buffer.

Smoking articles such as cigarettes are generally manufactured and packaged by a group of highly automated devices, including cigarette makers and wrappers, which are assembled from raw materials such as cigarette ore, wrapping paper, filter parts and tipping paper , Bundles of smoking articles are aligned and packaged in containers such as hinge lid containers.

In such a group of automation devices, a buffer is typically provided between the cigarette maker and the cigarette packing machine. The buffer acts as a reservoir of the formed smoking article in order to minimize the dependency between the cigarette maker and the wrapper.

Several operating parameters of the cigarette maker, buffer and cigarette packer must be preset to account for specific production requirements. Whenever such a group is operated to produce a cigarette having different characteristics (e.g., a different brand or design cigarette), certain operating parameters must be set to different specific values such that the group can be stably operated.

The cigarette maker and the cigarette packer operate independently at variable production rates. Generally, the cigarette maker and the cigarette packer operate at different predetermined production rates, so the buffer fill level varies with time.

If the buffer is only filled, the cigarette maker must be stopped and restarted only when the buffer filling level drops below the first maker threshold (cigarette maker start limit). To reduce the occurrence of cessation of the cigarette maker, it has been proposed to reduce the production rate of the cigarette maker when the buffer filling level generally exceeds a second maker threshold (cigarette maker deceleration limit) that is lower than the first maker threshold. This deceleration is a preset parameter of the cigarette maker.

If the buffer filling level decreases again to a value below the second manufacturer threshold, the production rate of the cigarette maker can be increased again. However, in order to limit the frequency at which the speed change of the cigarette maker occurs, it has been proposed to increase the production rate of the cigarette maker only when the buffer filling level falls below the second maker threshold by a predetermined amount (cigarette maker hysteresis width).

On the other hand, if the buffer is emptied, the cigarette packing machine must be stopped and restarted only when the buffer filling level reaches the first packager threshold (cigarette packer start limit). To reduce the occurrence of cessation of the cigarette packer, it has been proposed to reduce the production rate of the cigarette packer when the buffer filling level generally falls below a second packager threshold (cigarette packer deceleration limit) greater than the first packager threshold. This deceleration of the cigarette packing machine is a preset parameter of the cigarette packing machine.

If the buffer filling level again rises above the second packager threshold, the production rate of the cigarette packer can be increased again. However, in order to limit the frequency at which the speed change of the cigarette packing machine occurs, it has been proposed to increase the production speed of the cigarette packing machine only when the buffer filling level exceeds the second maker threshold value by a predetermined amount (cigarette packing hysteresis width).

Every time the cigarette maker is stopped, some cigarettes are rejected. Similarly, every time the cigarette packer is stopped, some cigarettes are rejected. In addition to the conditions identified above, the cigarette maker or cigarette packer may have to be shut down for other reasons, such as machine failure, lack of one or more of the starting materials, and the like. Also, during production, some cigarettes or cigarette packages or both may be found to fail to meet certain quality requirements and may be rejected. All such rejected products represent losses, so it would be desirable to limit the outage of cigarette making machines and cigarette packing machines.

In more general terms, it would be desirable to increase the productivity and overall efficiency of the group comprising the cigarette maker, the cigarette packer and the buffer. Indeed, the overall efficiency of one such group is the 'uptime', ie, the total number of cigarettes actually produced for a given time, and the number of cigarettes that could theoretically be produced As a ratio between the numbers of the first and second electrodes.

It would therefore be desirable to provide a method of controlling the operation of a group comprising a cigarette maker, a cigarette packer and a buffer interposed between the cigarette maker and the cigarette packer, thereby increasing the overall efficiency of the group. There is also a method of controlling the operation of one such group, for example by increasing the total output (expressed as the total number of cigarettes produced and packaged during a given time period) by reducing the number of rejects during production . It would also be desirable to provide a system that can implement one such method.

According to one aspect of the present invention there is provided a method of controlling operation of a group comprising a cigarette maker, a cigarette packer and a buffer, wherein the cigarette maker is upstream of the buffer with respect to the transport direction, And the group is constituted such that the operation of the cigarette maker and the cigarette packing machine depends on the filling level of the buffer. The method comprising: setting at least one operating parameter of the group correlating the operating state of the cigarette maker or cigarette packer with the filling level of the buffer to a starting value; And operating the group for a first cycle time based on the at least one operating parameter. The method also includes determining operating efficiency of the cigarette maker during a first cycle time; Determining an operating efficiency of the cigarette packing machine during a first cycle time; And determining the group comparison efficiency as a ratio between the operating efficiency of the cigarette maker and the operating efficiency of the cigarette packer. The method also includes, at the end of the first cycle time, resetting at least one operating parameter to an updated value according to group comparison efficiency.

BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 shows a qualitative embodiment of a parameter defining how the operation of the cigarette maker and the cigarette packer correlates with the level of filling of the buffer interposed between the cigarette maker and the cigarette packer;
Figure 2 is a flow chart showing the steps of the method according to the invention;
Figure 3 is a flow chart showing the steps of a preferred embodiment of the method according to the invention;
Figure 4 is a flow chart showing the steps of a further preferred embodiment of the method according to the invention.

According to another aspect of the present invention there is provided a system comprising a first group comprising a cigarette maker, a cigarette packer and a buffer, wherein the cigarette maker is upstream of the buffer with respect to the transport direction, The operation of the cigarette maker and the cigarette packing machine depends on the filling level of the buffer. The system also includes first sensor means for detecting the filling level of the buffer, the actual output of the cigarette maker, and the actual output of the cigarette packer; And a control device operatively connected to any one of the first group of cigarette makers, cigarette packers, buffers, or any combination thereof and configured to manage operation of the first group according to the method specified above.

It is to be understood that any feature described with reference to one aspect of the present invention may be equally applied to any other aspect of the present invention.

In contrast to known methods of operating a group of automated devices including a cigarette maker, a buffer and a cigarette packing machine, according to the present invention, it is possible to define how various automated devices of the group are operatively correlated (specifically, At least one of the parameters defining how the operation of the cigarette maker and the cigarette packer are affected by the filling level of the buffer) is adaptively adjusted as a function of the cigarette maker efficiency and the measured value of the cigarette packer efficiency.

The inventors have found that by managing the operation of such a group by the method according to the invention, the overall productivity and efficiency of the group can be advantageously increased in terms of both total cigarette production and uptime. In general, the effect of the non-uniform maximum production rate of the cigarette maker and the cigarette packer can advantageously be reduced.

The inventors have also found that the method according to the present invention can be applied to a group of plans (such as a pause for cleaning) so that the resulting apparent deviations of group efficiency do not affect the adaptive control logic underlying the method of the present invention And can be further optimized to handle everyday stops.

The term " cigarette maker " is used throughout this specification to refer to an automated apparatus configured to receive a cigarette, filter rod, wrapping paper, and tipping paper as raw materials and to form the raw material into a plurality of filter cigarettes. Cigarette making machines can generally be operated at maximum production rates and reduced production rates. Thus, the cigarette maker may be in one of several different operating states (e.g., maximum speed, reduced speed, stop). By " production speed " or " production rate " throughout this specification is meant the number of products produced for a given period of time (the number of cigarettes in a cigarette maker). By way of example, the production rate or production rate can be measured and expressed in terms of time / time.

Various forms and models of cigarette makers will be known to those skilled in the art. For example, one such automation device is PROTOS PM 100 (from Hauni Maschinenbau AG, Germany).

The term " cigarette packing machine " is used throughout this specification to refer to an automated device configured to receive a filter cigarette and packaging material, and to arrange and pack a bundle of filter cigarettes to form a pack of filter cigarettes. Is used. Cigarette packing machines can generally be operated at maximum production speed and reduced production speed. Thus, the cigarette packing machine can be in one of several different operating states (e.g., maximum speed, reduced speed, stop). In the case of a cigarette packer, the production rate or production rate refers to the number of products, i.e. the number of bags produced during a given time. Each pack contains a predetermined number of cigarettes, for example 20 packs / pack. Therefore, it is easier to compare and correlate the production rate of the cigarette packer with the production rate of the cigarette maker, since the production rate or production rate of the cigarette packer may conveniently be expressed as the number of packed cigarettes packed for a given time. Therefore, the production rate of the cigarette packing machine in the following will also be measured and expressed in terms of the ratio / time.

Various forms and models of cigarette wrappers will be known to those skilled in the art. For example, one such automation device is the F550 (from Focke GmbH, Germany).

The term " buffer " is used throughout this specification to refer to an automated device configured to receive a cigarette formed by a cigarette maker and deliver it to a cigarette packing machine.

Various forms and models of buffers will be known to those skilled in the art. One such automation device is CAPRICORN (ITM, The Netherlands).

As used herein, one or more " group of operating parameters " is referred to as a parameter that sets the dependency between the operating state of the cigarette maker or cigarette packer and the filling level of the buffer. In practice, the " operating parameter of the group " corresponds to a given filling level of the buffer configured to change the operating state of one or both of the cigarette maker and the cigarette packer.

One such operating parameter is, for example, the " cigarette maker deceleration limit ", i.e., the filling level of the buffer in which the production rate of the cigarette maker is reduced from the maximum rate to the reduced production rate.

Other such operational parameters of the group are:

Quot; cigarette maker start-up limit ", which is the filling level of the buffer in which the cigarette maker is restarted after stoppage caused by filling only the buffer;

Quot; cigarette maker hysteresis width ", which is the difference between the cigarette maker deceleration limit and the filling level of the buffer, in which the production rate of the cigarette maker is increased again from the reduced production rate to the maximum production rate;

Quot; cigarette packing machine deceleration limit ", which is the filling level of the buffer, in which the production speed of the cigarette packing machine is reduced from the maximum speed to the reduced production speed;

Quot; cigarette packing machine startup limit " which is the filling level of the buffer in which the cigarette packing machine is restarted after being stopped by the buffer being emptied; And

Quot; cigarette packer hysteresis width ", which is the difference between the cigarette packing machine deceleration limit and the filling level of the buffer, in which the production rate of the cigarette packing machine is increased again from the reduced production rate to the maximum production rate. Figure 1 qualitatively illustrates how these parameters can be related to one another.

The term " operating efficiency of a cigarette maker " is used throughout this specification to refer to the ratio between the actual production and the theoretical production of a machine, which is the number of cigarettes actually produced for a predetermined production time. The theoretical production is calculated by multiplying the scheduled production time by the maximum production rate of the cigarette maker.

The term " operating efficiency of a cigarette packer " is used throughout this specification to refer to the ratio between the actual production and the theoretical production of a machine, which is actually the number of packed cigarettes packed for a predetermined production time. The theoretical yield is calculated by multiplying the maximum production rate of the cigarette packer at the scheduled production time.

The method according to the invention is for controlling the operation of a group of automated devices comprising a cigarette maker, a cigarette packer and a buffer, wherein the cigarette maker is upstream of the buffer with respect to the transport direction and the cigarette packer has a buffer It is downstream. One such group is configured such that the operation of the cigarette maker and cigarette packer depends on the level of filling of the buffer in accordance with certain logic. In particular, the operating state of the cigarette maker or the cigarette packer, or both, is influenced by the filling level of the buffer. By way of example, the filling level of the buffer varies from 0% to 100%, so that the cigarette maker or cigarette packing machine is generally configured to operate at a maximum production rate or to be operated or stopped at a reduced production rate.

In the method according to the invention, at least one operating parameter of the group correlating the operating state of the cigarette maker or cigarette packer with the filling level of the buffer is set as the starting value, and the group is set to a predetermined value And is operated during the first cycle time.

The method also includes determining operating efficiency of the cigarette maker during a first cycle time; Determining an operating efficiency of the cigarette packing machine during a first cycle time; And determining the group comparison efficiency as a ratio between the operating efficiency of the cigarette maker and the operating efficiency of the cigarette packer. At the end of the first cycle time, the at least one operating parameter is reset to an updated value according to the group comparison efficiency.

Preferably, since the actual output of the cigarette maker and the actual output of the cigarette packer are continuously monitored, it is advantageously possible to determine the efficiency of the cigarette maker and the efficiency of the cigarette packer at any given time during the first cycle time. Alternatively, only the discrete values of the cigarette maker efficiency and the efficiency of the cigarette packer at a given moment during the first cycle time can be determined since the actual production of the cigarette packer can be detected at predetermined intervals during the first cycle time. The at least one parameter is reset to an update 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 maker and the cigarette packer is detected at least at the end of the first cycle time.

At least one operating parameter is reset to an updated value according to the group comparison efficiency as determined at the end of the first cycle time.

Therefore, in the method according to the present invention, the quality and range of the operating correlations between the cigarette dispenser and the buffer or cigarette packer and the buffer, or both, are modified while the group is operating. This means that even if the group is initially operated on a cigarette of a particular brand or type, i. E. With at least one parameter set to a starting value specifically selected for a given combination of raw material and production requirements, It is advantageous in that it is adaptively adjusted in consideration of the efficiency change.

Preferably, the at least one operating parameter is selected from the group consisting of a cigarette maker start limit, a cigarette maker deceleration limit, a cigarette maker hysteresis width, a cigarette packer start limit, a cigarette packer deceleration limit, and a cigarette packer hysteresis width. The inventors have found that by adjusting one or more of these parameters that establish a clear correlation between the operational state of the cigarette maker or cigarette packer and the filling level of the buffer adaptively according to the logic underlying the present invention, It is easy to improve the efficiency.

Advantageously, resetting the value of the at least one operating parameter comprises determining a correction value of at least one operating parameter as a function of group comparison efficiency at the end of the first cycle time.

In some embodiments, if the correction value of the at least one parameter is in 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 correction value. Alternatively, if the correction value of the at least one parameter is smaller 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 reset to the starting value.

In another embodiment, if the correction 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 reset to the correction value. If the correction value of the at least one parameter is smaller 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 correction 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.

It is therefore advantageously possible to ascertain whether at least one operating parameter is included in an acceptable range. This relates not only to the inherent constraints associated with the attributes of the group (e.g., that the filling level of the buffer can be from 0% to 100%), but also the fact that certain relationships between the various operating parameters are preferably maintained. As an example, the cigarette maker deceleration limit is preferably lower than the cigarette maker start limit. It is also advantageous in that the boundary value can be optimized such that the implementation of the method according to the invention leads to the most stable production increase.

Preferably, the step of determining the correction value of the at least one operating parameter comprises multiplying the baseline value of the at least one operating parameter by a factor substantially equal to the group comparison efficiency at the first cycle time end or an inverse thereof do.

The cigarette maker start-up limit defines the fill level of the buffer in which the cigarette maker is restarted after a stop caused by filling the buffer only. If the maximum production rate of the cigarette maker is faster than the maximum production rate of the cigarette packer (i.e., the bottleneck area is near the buffer filling level of 100%) while the cigarette maker efficiency remains constant and the cigarette packaging efficiency increases, The stoppage of the cigarette maker due to the filling of the cigarette maker will be reduced. Even when the maximum production speed of the cigarette packing machine is faster than the maximum production speed of the cigarette manufacturing machine (that is, when the bottle neck area is near the buffer filling level of 0%) while the efficiency of the cigarette manufacturing machine is kept constant and the cigarette packaging efficiency is increased The results are expected.

However, in the latter case, the occurrence of cessation of the cigarette maker will be slightly more greatly reduced. In fact, the amount of water in the buffer to be treated by the cigarette packing machine can be reduced before the cigarette maker can be restarted. Therefore, the starting limit of the cigarette packing machine can be regarded as being directly proportional to the efficiency of the cigarette packing machine. At the same time, the starting limit of the cigarette maker can be regarded as inversely proportional to the efficiency of the cigarette maker. Therefore, it can be regarded as follows:

The cigarette maker deceleration limit defines the filling level of the buffer in which the production rate of the cigarette maker is reduced from the maximum rate to the reduced production rate. If the maximum production rate of the cigarette maker is faster than the maximum production rate of the cigarette packer (i.e., the bottleneck area is near the buffer filling level of 100%) while the cigarette maker efficiency remains constant and the cigarette packaging efficiency increases, The stoppage of the cigarette maker due to the filling of the packer will be reduced because the packing machine is essentially more processed. On the other hand, if the maximum production rate of the cigarette packing machine is faster than the maximum production rate of the cigarette maker (i.e., the bottleneck area is near the buffer filling level of 0%), the efficiency of the cigarette maker is kept constant and the cigarette packing efficiency is increased , The frequency with which only the buffer is filled will be reduced more greatly. Therefore, the filling level range at which the cigarette maker is operated at deceleration can be reduced. This adds to the range of filling levels at which the cigarette maker can operate at maximum production speed, which is expected to lead to increased production.

Thus, the cigarette maker deceleration limit can be regarded as being directly proportional to the efficiency of the cigarette packing machine. At the same time, the cigarette maker deceleration limit can be regarded as inversely proportional to the efficiency of the cigarette maker. Therefore, it can be regarded as follows:

The hysteresis width of the cigarette maker is between the filling level of the buffer in which the production rate of the cigarette maker is reduced from the maximum production rate to the reduced production rate and the filling level of the buffer in which the production rate of the cigarette maker is increased again from the reduced production rate to the maximum production rate . If the maximum production rate of the cigarette maker is faster than the maximum production rate of the cigarette packer (i.e., the bottleneck area is near the buffer filling level of 100%) while the cigarette maker efficiency remains constant and the cigarette packaging efficiency increases, The possibility of stopping the cigarette maker due to the filling of the cigarette will be slightly increased. However, if the maximum production rate of the cigarette packing machine is faster than the maximum production rate of the cigarette maker (i.e., the bottleneck area is near the buffer filling level of 0%) while the efficiency of the cigarette maker is kept the same and the cigarette packaging efficiency is increased , The probability of the cigarette packing machine being stopped by the buffer being empty will increase. Thus, under such circumstances, the hysteresis width of the cigarette maker can be reduced to limit the effect of the bottleneck.

Thus, the hysteresis width of the cigarette maker can be regarded as inversely proportional to the efficiency of the cigarette packer. At the same time, the hysteresis width of the cigarette maker can be regarded as being directly proportional to the efficiency of the cigarette maker. Therefore, it can be regarded as follows:

The cigarette packing machine startup limit defines the filling level of the buffer in which the cigarette packing machine is restarted after being stopped by the buffer being emptied. If the maximum production rate of the cigarette maker is faster than the maximum production rate of the cigarette packer (i.e., the bottleneck area is near the 100% buffer filling level), and the cigarette packing machine efficiency remains constant and the efficiency of the cigarette maker increases, The occurrence of stoppage of the cigarette packing machine due to the emptying of the cigarette packing machine will be reduced. Thus, in order to improve production, the cigarette packing machine startup limit may be reduced so that the range of buffer filling level values in which the cigarette packing machine is effectively in a productive state is wider. However, if the maximum production speed of the cigarette packing machine is faster than the maximum production speed of the cigarette manufacturing machine, and the efficiency of the cigarette packing machine is kept constant and the efficiency of the cigarette maker is increased, the occurrence of stoppage of the cigarette packing machine due to buffer empty will decrease. Therefore, the cigarette packing machine startup limit should be reduced to a lesser extent. Therefore, the starting limit of the cigarette packing machine can be regarded as inversely proportional to the efficiency of the cigarette maker.

If the maximum production rate of the cigarette maker is faster than the maximum production rate of the cigarette packer and the efficiency of the packer is increased while the efficiency of the cigarette maker is kept constant, the likelihood of the buffer being emptied will also increase. Therefore, in order to improve the productivity, the starting limit of the cigarette packing machine must be increased. On the other hand, when the maximum production rate of the cigarette packing machine is faster than the maximum production rate of the cigarette maker, and the efficiency of the packaging machine is increased while the efficiency of the cigarette maker is equal, the empty state of the buffer is much more frequently Will occur. Thus, in one such case, the cigarette packing machine startup limit should be increased even more. Therefore, the starting limit of the cigarette packing machine can be regarded as being directly proportional to the efficiency of the cigarette packing machine. Therefore, it can be regarded as follows:

The cigarette packer deceleration limit defines the level of filling of the buffer in which the production rate of the cigarette packer is reduced from the maximum rate to the reduced production rate. If the efficiency of the cigarette packing machine is increased when the maximum production speed of the cigarette maker is faster than the maximum production speed of the cigarette packing machine and the efficiency of the cigarette maker is kept the same, the occurrence of cessation of the cigarette packing machine will increase, Because it produces more. Under these conditions, the cigarette packing machine deceleration limit can advantageously be reduced. On the other hand, if the maximum production rate of the cigarette packing machine is faster than the maximum production rate of the cigarette maker, and the efficiency of the packing machine is increased when the efficiency of the cigarette maker is the same, the deceleration limit of the cigarette packing machine should be much higher, It is likely to be emptied. Thus, the cigarette packing machine deceleration limit can be regarded as being directly proportional to the efficiency of the cigarette packing machine.

If the maximum production rate of the cigarette maker is faster than the maximum production rate of the cigarette packer and the efficiency of the cigarette maker is increased, the possibility of the buffer being empty will be less. Thus, under these conditions, the cigarette packing machine deceleration limit can be reduced. On the other hand, when the maximum production rate of the cigarette packing machine is faster than the maximum production rate of the cigarette maker, the reduction of the cigarette packing machine deceleration limit is not so important because the bottleneck area is close to the 0% buffer filling level. Therefore, it can be regarded as follows:

The hysteresis width of the cigarette packing machine hysteresis width is a function of the filling level of the cigarette packing machine with the production rate of the cigarette packing machine being reduced from the maximum production rate to the reduced production rate (i.e., Lt; RTI ID = 0.0 > a < / RTI > If the maximum production rate of the cigarette maker is faster than the maximum production rate of the cigarette packer, most of the production period design buffer filling level will be close to 100%. If the efficiency of the cigarette making machine is increased when the efficiency of the cigarette packing machine is kept constant, the number of times of stopping the cigarette packing machine will increase. On the other hand, if the maximum production speed of the cigarette packing machine is faster than the maximum production speed of the cigarette manufacturing machine, the greater the efficiency of the cigarette packing machine, the greater the number of stops of the packaging machine. In order to cope with this effect, the hysteresis width of the cigarette packing machine is increased, and the influence of stopping the cigarette packing machine can be reduced. Therefore, the hysteresis width of the cigarette packing machine can be regarded as being directly proportional to the efficiency of the cigarette packing machine.

If the maximum production rate of the cigarette maker is faster than the maximum production rate of the cigarette packer, the efficiency of the cigarette maker is the same and the efficiency of the maker increases, the possibility of filling up the buffer will increase and thus the cigarette maker will also stop more frequently will be. Under these conditions, the hysteresis width of the cigarette packer can be reduced so that the packer can be operated at full speed for as long as possible. Similar results may be obtained when the maximum production speed of the cigarette packer is faster than the maximum production speed of the cigarette maker. Therefore, the hysteresis width of the cigarette packing machine can be regarded as inversely proportional to the efficiency of the cigarette maker. Therefore, it can be regarded as follows:

In view of these, the inventors have found that the correction value of at least one operating parameter is advantageously determined by multiplying 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, Can be. Therefore, a substantially linear relationship is always established between the ratio between the efficiency of the cigarette packing machine and the efficiency of the cigarette maker, or the inverse thereof and at least one parameter.

Preferably, the baseline value for at least one parameter is determined as the value of the at least one parameter, and the value of the at least one parameter is selected such that the efficiency of the cigarette maker is less than or equal to the productivity of the group . This can be achieved, for example, by simulating the operation of the group, so that the effect on the productivity when the baseline value for at least one parameter has different values is conveniently evaluated without having to actually actuate the group .

During the group operation, several additional cycles may follow after the first cycle. Preferably, the actual yield of the cigarette maker, the actual yield of the cigarette packer, and the operating efficiency of the cigarette maker are continuously monitored for an additional cycle time. Thus, it is advantageously possible to determine the current value of the efficiency of the cigarette maker or the efficiency of the cigarette packer, or both, at any given time during any additional cycle time. However, the output of the cigarette maker and the output of the cigarette packer may alternatively be measured at predetermined intervals for any additional cycle time. In some preferred embodiments, the method further comprises: operating the group for an additional cycle time based on the updated at least one operating parameter; Determining an operating efficiency of the cigarette maker over an additional cycle time; Determining an operating efficiency of the cigarette packing machine over an additional cycle time; And determining the group comparison efficiency as the ratio between the operating efficiency of the cigarette maker at the end of the additional cycle time and the operating efficiency of the cigarette packer. If the group comparison efficiency at the end of the additional cycle time is at least 5% different from the group comparison efficiency at the start of the additional cycle time, the at least one operating parameter is reset to the additional update value according to the group comparison efficiency at the end of the additional cycle time . Alternatively, if the group comparison efficiency at the end of the additional cycle time differs from the group comparison efficiency at the start of the additional cycle time by less than 5%, at least one operating parameter remains unchanged.

This is advantageous in that confirmation is performed to determine whether the operation of the automation device of the group has significantly changed between the start and end of the additional cycle. This is evaluated by measuring whether there has been any change in the group comparison efficiency between the start and end of the additional cycle. If the operation of any one of the group's automation devices has not substantially changed, there is in fact no need to reset at least one parameter. On the other hand, if a change has occurred associated with the operation of any one of the group's automation devices, it is desirable to reset at least one parameter with an update value that describes the change.

Advantageously, the step of resetting the at least one operating parameter comprises at least one actuation according to the value of the ratio between the measured / determined actuation efficiency of the cigarette packer and the measured / determined actuation efficiency of the cigarette maker at the end of the additional cycle time And determining an additional update value of the parameter. If the updated value of the at least one parameter is within a range from a predetermined lower boundary value of the at least one parameter to a predetermined upper boundary value of the at least one parameter, the at least one operating parameter is reset to the determined updated value. Alternatively, if the update value of at least one parameter is smaller than a predetermined lower boundary value of at least one parameter or greater than a predetermined upper boundary value of at least one parameter, then at least one operating parameter is not changed.

Alternatively, the step of resetting the value of the at least one operating parameter may comprise determining an additional update value of the at least one operating parameter according to the value of the group comparison efficiency at the end of the additional cycle time. If the additional update 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 additional update value. If the additional update 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 additional update 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, an acknowledgment as to whether the additional update value is within the acceptable range is repeated at the end of each additional cycle. This is advantageous in that it ensures operational stability of the group during production.

In an alternative embodiment, the method includes operating the group for a predetermined additional cycle time based on the updated at least one operating parameter; Determining an operating efficiency of the cigarette maker over an additional cycle time; Determining an operating efficiency of the cigarette packing machine over an additional cycle time; And determining the group comparison efficiency as the ratio between the operating efficiency of the cigarette maker at the end of the additional cycle time and the operating efficiency of the cigarette packer.

If the operating efficiency of the cigarette maker at the end of the additional cycle time is less than the baseline maker efficiency, then the average maker efficiency during the additional cycle time is assumed as the current value of the operating efficiency of the cigarette maker. Alternatively, when the operating efficiency of the cigarette maker at the end of the additional cycle time is at least as large as the efficiency of the baseline maker, the operating efficiency of the cigarette maker at the end of the additional cycle time is assumed as the current value of the operating efficiency of the cigarette maker.

If the operating efficiency of the cigarette packing machine at the end of the additional cycle time is less than the baseline packer efficiency, then the average baseline packer efficiency for the additional cycle time is assumed as the current value of the operating efficiency of the cigarette packer. Alternatively, when the operating efficiency of the cigarette packing machine at the end of the second cycle time is at least as large as the baseline packer efficiency, the operating efficiency of the cigarette packing machine at the end of the second cycle time is assumed as the current value of the operating efficiency of the cigarette packing machine.

In this alternative embodiment, the method further comprises determining a current group comparison efficiency as a ratio between a current value of the operating efficiency of the cigarette maker and a current value of the operating efficiency of the cigarette packer. Then, if the current group comparison efficiency is different by at least 5% from the comparison efficiency of the group at the start of the additional cycle time, the at least one operating parameter is reset to the additional update value according to the current group comparison efficiency. Alternatively, if the current group comparison efficiency differs from the comparison efficiency of the group at the start of the additional cycle time by less than 5%, at least one operating parameter remains unchanged.

By taking into account the average value of the efficiency of the automated devices in the group, it is possible that the buffer filling level does not reach 100% or 0% but can be caused by the cessation of the cigarette maker or cigarette packer caused by other reasons such as planned production interruptions It is advantageously possible to halve possible inconveniences.

Advantageously, resetting the value of the at least one operating parameter comprises determining an additional update value of the at least one operating parameter based on the group comparison efficiency.

In some embodiments, if the additional update value of the at least one parameter is in 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 additional update value . Alternatively, if the additional update value of the at least one parameter is smaller 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 remains unchanged.

In an alternative embodiment, if the additional update value of the at least one parameter is in 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 do. Alternatively, if the additional update 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 additional update 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 implementing a method according to the invention comprises a first group comprising a cigarette maker, a cigarette packer and a buffer, wherein the cigarette maker is upstream of the buffer with respect to the transport direction and the cigarette packer is downstream of the buffer with respect to the transport direction . The operation of the cigarette making machine and the cigarette packing machine depends on the filling level of the buffer. The system further comprises first sensor means for detecting the filling level of the first group of buffers and for measuring the yield of the cigarette maker and the yield of the cigarette packer. The system also includes a control device operatively connected to any one of the cigarette maker, the cigarette packer, the buffer, or any combination thereof, and configured to manage the operation of the first group according to the method specified above.

The control device is fundamentally configured to implement the control logic according to the method described above. Thus, the control device not only ensures that the filling levels of the cigarette maker and the cigarette packer and buffer are correlated with one another, but also the nature and quality of such a correlation over time to adapt to possible changes in the efficiency of the cigarette maker or cigarette packer, Is verified and changed.

In some embodiments, one such system includes an additional group comprising a cigarette maker, a cigarette packer, and a buffer, wherein the cigarette maker is upstream of the buffer with respect to the transport direction and the cigarette packer is positioned downstream of the buffer with respect to the transport direction Therefore, the operation of the cigarette maker and the cigarette packer depends on the filling level of the buffer. The system also includes second sensor means for detecting the filling level of the second group of buffers and for measuring the yield of the cigarette maker and the yield of the cigarette packer. The control device is operatively connected further to any one of a cigarette maker, a cigarette packer, a buffer, or any combination thereof, and is configured to manage the operation of the first group and the additional group according to the method set forth above.

This is advantageous in that in a system in which two or more such groups of automation devices are run in parallel, the same logic can be implemented in the various groups based on observations of the operation of all automation devices in the system. Thus, the overall productivity of the system can be advantageously improved.

The invention will be further described, by way of example only, with reference to the accompanying drawings, in which:

Figure 1 shows a number of operating parameters of a group comprising a cigarette maker, a cigarette packer and a buffer. The parameter correlates the operating state of the cigarette maker and the cigarette packer with the filling level of the buffer. Parameters include cigarette maker start limit, cigarette maker deceleration limit, cigarette maker hysteresis width, cigarette packer start limit, cigarette packer deceleration limit, cigarette packer hysteresis width.

One such group was set up as a cigarette maker (PROTOS PM 100 from Hauni Maschinenbau AG, Germany), F550 (from Focke GmbH, Germany) and CAPRICORN (from ITM, The Netherlands) as buffers. The PROTOS PM 100 has a maximum production rate of 10,000 units per minute. The F550 has a maximum production rate of 500 cubic feet per minute, with 20 cubic cigars per cubic meter (equivalent to processing 10,000 cigarettes per minute). CAPRICORN has a variable capacity of 125,000 units, and the upstream and downstream speeds are 10,000 units / min.

Baseline values for the enumerated operating parameters were determined based on the results of simulations performed on the assumption that the operating efficiency of the cigarette maker was substantially the same as the operating efficiency of the cigarette packer. Group productivity was optimized by selecting a baseline value as the value of the operating parameter. The following table 1 lists the baseline values determined from the simulation.

Boundary values for operating parameters have been set for stable operation of the group. Table 2 below lists the boundary values.

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

The operating parameters of the group are set to their respective starting values, and the group is operated for a first cycle time of one hour. During this time, the operation of the group is monitored to determine the operating efficiency of the cigarette maker, the operating efficiency of the cigarette packer, and the ratio of those considered to be the group comparison efficiency.

After one hour, the correction value of the operating parameter is determined as a function of the group comparison efficiency. Therefore, the update value of the cigarette maker start-up limit is calculated by multiplying the relevant baseline value by the determined value of the group comparison efficiency (see Equation 1). Similar calculations are performed on cigarette maker deceleration limits, cigarette packer start limit, cigarette packer deceleration limit, and cigarette packer hysteresis width (see equations 2, 4, 5, and 6). The update value of the hysteresis width of the cigarette maker is calculated by multiplying the relevant baseline value by the reciprocal of the determined value of the group comparison efficiency.

The operating parameters are reset to these updated values. The group runs for an additional cycle time of one hour. At the end of the additional cycle time, the group comparison efficiency is again determined. If the group comparison efficiency has changed by at least 5% between the start and end of the additional cycle time, a new update value for the operating parameter is calculated as above and the operating temperature is reset to this update value. Alternatively, if the group comparison efficiency changes to less than 5% between the start and end of the additional cycle time, the operating parameters are not changed.

Compared with the same group operated without adaptive control, the operation time increased about 0.25% when the group was operated according to the method as shown in FIG.

Figure 3 shows a second embodiment of the method according to the invention. Here, only the difference from the embodiment of Fig. 2 will be described.

The method shown by the flowchart of FIG. 3 differs from the above-described embodiment in that additional verification is performed immediately after the update value of the operating parameter is determined. In practice, each update value of the operating parameter is compared with the corresponding boundary value. If the update value is within the boundary value, the update value is used to reset the value of the operating parameter. Alternatively, 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 update value is below the lower boundary, the lower boundary value is used to reset the value of the operating parameter.

Compared to the same group operated without adaptive control, the run time increased from about 0.6% to about 0.8% when the group was operated according to the method as shown in FIG.

Figure 4 shows a third embodiment of the method according to the invention. Here, only the difference from the embodiment of Fig. 3 will be described.

The method shown by the flowchart of FIG. 4 differs from the above-described embodiment in that additional verification is performed immediately after the update value for the operating parameter is determined. In practice, the current value of the cigarette maker efficiency and the current value of the cigarette packer efficiency are compared with the baseline efficiency value (e.g., 30%). If the current value of the cigarette maker efficiency and the current value of the cigarette packer efficiency are at least equal to the associated baseline value, then the current values of the cigarette maker efficiency and the cigarette packer efficiency are used for subsequent verification of the change in efficiency over the additional cycle time. Alternatively, if the current value of the cigarette maker efficiency and the current value of the cigarette packer efficiency are below the relevant baseline value, then the average value of the cigarette maker efficiency and cigarette packer efficiency is used for subsequent confirmation of the change in efficiency over the additional cycle time do.

Compared with the same group operated without adaptive control, the run time increased about 0.9% when the group was operated according to the method as shown in FIG. This will increase the production of more than 385,000 cigarettes over the three-day production period.

Claims (13)

A method for controlling the operation of a group comprising a cigarette maker, a cigarette packer and a buffer, said cigarette maker being upstream of said buffer with respect to the transport direction, said cigarette packer being downstream of said buffer with respect to the transport direction, Group is configured such that operation of said cigarette maker and said cigarette packer is dependent on the level of filling of said buffer)
The method comprising:
Setting at least one operating parameter of the group correlating the operating state of the cigarette maker or cigarette packer with the filling level of the buffer to a starting value;
Operating the group for a predetermined first cycle time based on the at least one operating parameter;
Determining operating efficiency of the cigarette maker over the first cycle time;
Determining operating efficiency of the cigarette packing machine over the first cycle time;
Determining group comparison efficiency as a ratio between an operating efficiency of the cigarette maker and an operating efficiency of the cigarette packer; And
At the end of the first cycle time, resetting the at least one operating parameter to an updated value according to the group comparison efficiency. 2. The method of claim 1 wherein the at least one operating parameter is selected from the group consisting of a cigarette maker start limit, a cigarette maker deceleration limit, a cigarette maker hysteresis width, a cigarette packer start limit, a cigarette packer deceleration limit, a cigarette packer hysteresis width, Way. 3. The method of claim 1 or 2, wherein the step of resetting the value of the at least one operating parameter comprises:
Determining a correction value of the at least one operating parameter as a function of the group comparison efficiency at the end of the first cycle time;
Resetting the at least one operating parameter to the correction value if the correction 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; And
Resetting the at least one operating parameter to the startup value if the correction 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 How to. 3. The method of claim 1 or 2, wherein the step of resetting the value of the at least one operating parameter comprises:
Determining a correction value of the at least one operating parameter as a function of the group comparison efficiency at the end of the first cycle time;
Resetting the at least one operating parameter to the correction value if the correction 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;
Resetting the at least one operating parameter to a lower boundary value of the at least one parameter if the correction value of the at least one parameter is less than the lower boundary value of the at least one parameter; And
And resetting the at least one operating parameter to an upper boundary value of the at least one parameter if the correction value of the at least one parameter is greater than the upper boundary value of the at least one parameter. 5. The method according to claim 3 or 4, wherein said step of determining a correction value of said at least one operating parameter is based on a difference between a baseline value of said at least one operating parameter and said group comparison efficiency at the end of said first cycle time By the same factor or its reciprocal. 6. The method according to any one of claims 1 to 5,
Operating the group for an additional cycle time based on the updated at least one operating parameter;
Determining operating efficiency of the cigarette maker over the additional cycle time;
Determining operating efficiency of the cigarette packing machine over the additional cycle time;
Determining a group comparison efficiency as a ratio between an operating efficiency of the cigarette maker at the end of the additional cycle time and an operating efficiency of the cigarette packing machine;
Wherein the group comparison efficiency at the end of the additional cycle time is different by at least 5% from the group comparison efficiency at the beginning of the additional cycle time, the at least one operating parameter To an additional update value;
Maintaining said at least one operating parameter unchanged if said group comparison efficiency at said additional cycle time-out is less than 5% with said group comparison efficiency at the beginning of said additional cycle time. 6. The method according to any one of claims 1 to 5,
Operating the group for a predetermined additional cycle time based on the adjusted at least one operating parameter;
Determining operating efficiency of the cigarette maker over the additional cycle time;
Determining operating efficiency of the cigarette packing machine over the additional cycle time;
Determining a group comparison efficiency as a ratio between an operating efficiency of the cigarette maker at the end of the additional cycle time and an operating efficiency of the cigarette packing machine;
If the operating efficiency of the cigarette maker at the end of the additional cycle time is less than the baseline maker efficiency, assuming an average maker efficiency during the additional cycle time as a current value of the operating efficiency of the cigarette maker;
Assuming the operating efficiency of the cigarette maker at the end of the additional cycle time as the current value of the operating efficiency of the cigarette maker when the operating efficiency of the cigarette maker at the end of the additional cycle time is at least as great as the efficiency of the baseline maker ;
If the operating efficiency of the cigarette packing machine at the end of the additional cycle time is less than the baseline packing machine efficiency, assuming an average packing efficiency for the additional cycle time as a current value of the operating efficiency of the cigarette packing machine;
The operating efficiency of the cigarette packing machine at the end of the second cycle time is set as a current value of the operating efficiency of the cigarette packing machine when the operating efficiency of the cigarette packing machine at the end of the second cycle time is at least as large as the efficiency of the baseline packing machine ;
Determining group comparison efficiency as a ratio between a current value of the operating efficiency of the cigarette maker and a current value of the operating efficiency of the cigarette packing machine; And
Resetting the at least one operating parameter to an additional update value according to the current group comparison efficiency if the current group comparison efficiency is different by at least 5% from the group comparison efficiency at the start of the additional cycle time;
And maintaining the at least one operating parameter unchanged if the current group comparison efficiency is less than 5% with the group comparison efficiency at the start of the additional cycle time. 7. The method of claim 6, wherein the step of resetting the value of the at least one operating parameter comprises:
Determining an additional update value of the at least one operating parameter based on a ratio value between the measured / determined operating efficiency of the cigarette maker at the end of the additional cycle time and the measured / determined operating efficiency of the cigarette packager;
Resetting the at least one operating parameter to the determined updated value 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 step;
Maintaining the at least one operating parameter unchanged if the updated value of the at least one parameter is less than a predetermined lower boundary value of the at least one parameter or greater than a predetermined upper boundary value of the at least one parameter ≪ / RTI > 7. The method of claim 6, wherein the step of resetting the value of the at least one operating parameter comprises:
Determining an additional update value of the at least one operating parameter based on the value of the group comparison efficiency at the end of the additional cycle time;
Resetting the at least one operational parameter to the additional update value if the additional update 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 step;
Resetting the at least one operating parameter to a lower boundary value of the at least one parameter if the additional update value of the at least one parameter is less than the lower boundary value of the at least one parameter; And
And resetting the at least one operating parameter to an upper boundary value of the at least one parameter if the additional update value of the at least one parameter is greater than the upper boundary value of the at least one parameter. 8. The method of claim 7, wherein the step of resetting the value of the at least one operating parameter comprises:
Determining an additional update value of the at least one operating parameter based on a current comparison efficiency of the group;
Resetting the at least one operational parameter to the additional update value if the additional update 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 step; And
Maintaining the at least one operating parameter unchanged if the additional update value of the at least one parameter is less than a lower boundary value of the at least one parameter or greater than an upper boundary value of the at least one parameter How to. 8. The method of claim 7, wherein the step of resetting the value of the at least one operating parameter comprises:
Determining an additional update value of the at least one operating parameter based on the current group comparison efficiency;
Resetting the at least one operational parameter to the additional update value if the additional update 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 step;
Resetting the at least one operating parameter to a lower boundary value of the at least one parameter if the additional update value of the at least one parameter is less than the lower boundary value of the at least one parameter; And
And resetting the at least one operating parameter to an upper boundary value of the at least one parameter if the additional update value of the at least one parameter is greater than the upper boundary value of the at least one parameter. A cigarette maker, a cigarette maker, a cigarette maker, a cigarette maker, a cigarette maker, a cigarette maker, a cigarette maker, a cigarette maker, a cigarette maker, Wherein the operation of said buffer is dependent on the level of filling of said buffer;
First sensor means for detecting a filling level of said buffer of said first group and for measuring a production amount of said cigarette manufacturing machine and a production amount of said cigarette packing machine; And
A second group of cigarette makers, a cigarette packer, a buffer, or any combination thereof, operatively connected to the first group of actuators in accordance with the method set forth in any one of claims 1 to 11 The system comprising: 13. The cigarette making machine of claim 12, further comprising a cigarette maker, a cigarette packer and a buffer, wherein the cigarette maker is upstream of the buffer with respect to the transport direction and the cigarette packer is downstream of the buffer with respect to the transport direction, The operation of the cigarette maker and the cigarette packing machine depending on the level of filling of the buffer); And
And second sensor means for detecting the filling level of the buffer of the second group and measuring the production amount of the cigarette manufacturing machine and the production amount of the cigarette packing machine,
Wherein the control device is operably connected further to any one of the second group of cigarette making machines, cigarette packing machines, buffers or any combination thereof, and is operable according to the method set forth in any one of claims 1 to 11 And manage the operation of the first group and the further group.

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