WO2024051976A1 - Procédé de commande de processus de traitement de récipients et système de traitement de récipients pour la production, le remplissage, la manipulation, l'emballage et/ou le transport de récipients - Google Patents

Procédé de commande de processus de traitement de récipients et système de traitement de récipients pour la production, le remplissage, la manipulation, l'emballage et/ou le transport de récipients Download PDF

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Publication number
WO2024051976A1
WO2024051976A1 PCT/EP2023/065746 EP2023065746W WO2024051976A1 WO 2024051976 A1 WO2024051976 A1 WO 2024051976A1 EP 2023065746 W EP2023065746 W EP 2023065746W WO 2024051976 A1 WO2024051976 A1 WO 2024051976A1
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WIPO (PCT)
Prior art keywords
packaging
sensor
handling
containers
conveying
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PCT/EP2023/065746
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German (de)
English (en)
Inventor
Florian Kästner
Marcus KREIS
Johann LUBER
Thomas-Florian MAYER
Marcus SEIDL
Herbert Spindler
Stefan Willnhammer
Marcel Bien
Andreas Puetz
Original Assignee
Krones Aktiengesellschaft
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Application filed by Krones Aktiengesellschaft filed Critical Krones Aktiengesellschaft
Publication of WO2024051976A1 publication Critical patent/WO2024051976A1/fr

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    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B19/00—Programme-control systems
    • G05B19/02—Programme-control systems electric
    • G05B19/418—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM]
    • G05B19/41875—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM] characterised by quality surveillance of production

Definitions

  • the present invention relates to a method for controlling production, handling, packaging and/or conveying processes of containers with liquid or pasty products contained therein, as well as a system for the production, filling, handling, packaging and/or conveying of containers with contained therein liquid or pasty products.
  • the containers to be filled which are normally filled with beverages or other liquids, are subjected to a variety of transport and treatment steps.
  • the containers are provided ready for use or are first brought into their intended shape from preforms using blow molding machines, they are filled, labeled and packaged according to grouping processes during their transport route.
  • the packaging of several filled containers can be done, for example, using shrink films, packaging blanks and/or using outer packaging made of paper or cardboard.
  • the packaging units formed in this way can then, if necessary, be palletized and stacked in pallet layers in order to make them ready for shipping and transportable into large units.
  • containers are often transported in the so-called aisle inlet to a packaging machine, with the positions of numerous transported containers conventionally being detected by sensors.
  • the packaging machines are also connected to the subsequent palletizing systems via transport routes, which in turn can be monitored using sensors.
  • a transport device and a method for transporting and distributing beverage containers that are transported in several parallel conveyor lanes can be found, for example, in DE 102020 120 336 A1. You can find it there as an option In addition, sensory detection of the container flow and, if necessary, robot-assisted influencing of the container flow.
  • the present invention proposes a method for controlling production, handling, packaging and/or conveying processes of containers with liquid or pasty products contained therein with the features of the independent method claim.
  • at least one process parameter is determined using sensors, which is suitable for providing an essential quality statement about the monitored part of the process.
  • at least one such process parameter is monitored and determined using sensors, which can provide an indication of a disruption in at least parts of the processes.
  • the specialist entrusted with the problems of precise process monitoring and maintaining trouble-free processing operations in the systems considered here generally has powerful electronic data processing systems available to support them. For this reason, the expert is usually aware that only powerful signal processing data evaluation enables him to appropriately classify the disturbances that have occurred and are detected by sensors in the process flow, for example into disturbances that occur due to wear or into atypical disturbances that are not can be clearly assigned to effects that are usually due to wear and tear on container treatment or conveying devices or similar devices. Depending on the classification made, different options for action are available, which will be briefly discussed below.
  • an identified error which can be derived in particular from sensory abnormalities or from deviations from defined target values, has been classified as a wear-related error
  • an error value classified in this way can be subjected to a supplementary evaluation.
  • an error event that changes over a defined period of time and is recognized and processed as a wear-indicating error event
  • it can make sense to predict future events from this. For example, a reasonably reliable statement about the service life of individual components or system modules can be derived from error evaluation and a comparison with corresponding data.
  • forecasts about future events and/or probabilities of default are possible.
  • Such a forecast can be, for example, a likely expected running time or remaining running time of the wear-prone system module and thus of the entire system, so that from such a supplementary error analysis it can be estimated more or less precisely at what point in time at the latest an adapted maintenance of the system module or the entire system will be necessary in order to be able to replace at least the components that are subject to wear and are therefore no longer fulfilling their task satisfactorily.
  • the operational safety of the system can be significantly improved and the probability of failure significantly reduced, since the extended error analysis can be used as a forecasting tool for the service life of gradually and continuously wearing components.
  • the wear limit of the affected component whose wear can be recorded directly or indirectly using the sensor evaluation, determines the remaining running time of the affected system module and can specify sensible maintenance cycles to the control center in order to avoid unplanned system downtimes.
  • the selected sensor-determined values of the at least one process parameter are continuously updated Interruptions or cyclically and at recurring intervals are recorded and stored in order to be made available for data evaluation and processed there.
  • a recording mode can be useful in which the intervals for recording the process parameters are shortened if error messages previously occurred more frequently or in larger numbers.
  • the stored sensor values can be evaluated in different ways or with different viewing directions. In particular, it can be useful to evaluate the stored values with regard to an accumulation of deviations from defined target value ranges within defined time periods and/or in connection with previously made process modifications in order to be able to make statements about the process parameters of interest, particularly in connection with disruptions or disruptive processes or events in the process.
  • a number of detected exceedances or undershoots of the limit values specified by the respective setpoint ranges and/or an extent of the deviation from the respective setpoint range are determined, so that if a defined one is exceeded Number of deviations from the respective setpoint range or a deviation from the respective setpoint range that exceeds a given extent or with a combination of the deviations mentioned defines an event and from this a control parameter can be generated for process-influencing or process-changing control specifications in the method.
  • the method can also make sense to store the sensor-determined values of the at least one process parameter in a database in order to be able to continuously make them available for data evaluation.
  • the event defined above can therefore be derived at any time from the data evaluation, whereby different target values can be specified and/or the permitted number of deviations from the respective target value range can be varied as required.
  • a sensor-determined parameter value within the predetermined setpoint range can be approximated in this way be correlated with a trouble-free section of the respective production, handling, packaging and/or conveying process.
  • an accumulation of exceedances of the setpoint range that remains below a predetermined limit value can be correlated with a section of the respective production, handling, packaging and/or conveying process that runs smoothly and meets predetermined quality requirements.
  • Processing the event can be done in different ways.
  • an error event is derived from the defined event, which is simply saved and made available for further consequences for the system control.
  • control parameters can, in particular, initiate or bring about sensible corrections in the process flow, which can either contribute to maintaining the production, handling, packaging and/or conveying process in progress or to improving it, that is to say to a reduction in the influence of disruptions or the susceptibility to disruptions.
  • a control signal can be generated for one or more actuators, which react appropriately to the process flow, for example by controlling conveyor drives or control or Steering devices located in the conveyor path for container transport.
  • an error event is derived from the defined event, which is at least stored, made available in data processing for further processing steps and preferably visualized via a user interface such as a display device or the like or in some other way is made accessible to users.
  • the error events can be processed and/or modified in different ways by the automated data processing and/or by the user before they are used, if necessary, as process-changing or process-influencing manipulated variables.
  • the process-influencing or process-changing control specifications generated by the data processing device processing the sensor data are used in such a way that at least one actuator is controlled, which particularly affects the affected section of the respective production, handling, packaging and/or conveying process and changes a process parameter.
  • measured wear which can be derived from a more or less continuously increasing error value, can be used not only to control actuators, but in the manner already explained above to predict the failure probabilities of affected components that cause the wear-related error values.
  • the increasing wear measurement values advantageously provide meaningful information about the remaining running time before a wear limit that can still be tolerated is reached. Such forecasts can also be made using the method according to the invention without requiring direct intervention in the system control.
  • the process parameters to be changed or influenced can, for example, mean all conceivable partial aspects of the process referred to here, whether this a blow molding machine, a filling module, a labeling module, a conveyor section or another part of a container treatment system.
  • control specifications are implemented using actuators, one goal of such controlling interventions in the individual process sections is essentially to reduce or eliminate the setpoint deviations.
  • the control specifications for the method derived from the generated control commands to significantly reduce the extent to which the defined number of deviations of the parameter values from the respective setpoint range is exceeded or, in the best case, to even completely eliminate the deviations, which in turn is achieved by sensory monitoring can be recognized and processed.
  • a closed control loop for process optimization can therefore be formed through appropriate controlling interventions in the process.
  • control specifications for the method derived from the derived control command reduce the extent of the deviations of the parameter values from the respective setpoint range, ideally to a value of zero or approximately zero. Since these interventions and the effects achieved as a result can also be monitored using sensors, the feature of the closed control loop is also fulfilled in this way, so that the method under consideration is not just a classic monitoring and control method for container processing and container handling processes of a wide variety of types, but it can also be a regulatory procedure.
  • a further problem that has not yet been considered here is that an accumulation of certain error messages cannot be noticed immediately because the time intervals between occurring faults and the associated error messages are relatively long. If, for example, the supervisors work in shifts, then it may be a question of documentation and/or communication when handing over the shift as to whether previously occurring disruptions receive the attention they deserve. If the error message only occurs once per shift for each operator, but such an error occurs in every shift, then it can be said that the fault is common. Nevertheless, there is a not insignificant risk that such an accumulation will not be noticed or will only be noticed with a delay if there is no or insufficient communication between the operators of successive shifts. Overall, the model situation described shows that the documentation and storage of faults and error messages can be subject to certain randomness. These coincidences should be able to be largely eliminated with the help of the method regulations according to the invention, which would achieve an essential aim of the present invention.
  • the recorded process parameters that indicate a malfunction are stored, evaluated and classified in such a way that a priority is assigned to the error messages as part of the evaluation. If the same error message occurs several times within a defined period of time, then it makes sense to assign a higher priority to such a fault. If the priority reaches a certain limit or threshold value, then corresponding information can be generated, which can, for example, contain an instruction to the operator of the corresponding system section or system module to carry out a corresponding functional test within a predetermined time frame. This information can in particular represent an event or error event according to the above definition, from which a control parameter for process-influencing or process-changing control specifications in the method can be generated, which includes the additional option of carrying out control interventions.
  • a packaging module can be considered in which primary packaging to be packaged, formed for example by beverage containers or bottles, is recorded in groups in a secondary packaging, formed for example by an outer packaging box, and stored in groups be arranged in the secondary packaging mentioned.
  • a secondary packaging formed for example by an outer packaging box
  • the bottles can be grouped and arranged in the outer packaging.
  • Appropriately equipped gripper modules can be used to grip the groups of bottles, with gripper heads with gripper tulips having proven successful in practice, so that each bottle to be gripped is gripped by one of the gripper tulips arranged in the gripper head.
  • a sensible control parameter could, for example, be to control the affected gripper tulip with a moderately increased suction pressure consist. If such a measure can reduce the frequency of errors, which in turn can be detected by appropriate evaluation of the sensory monitoring of the pickup quality of the gripper head, the increased suction pressure is preferably maintained, thereby creating a closed control loop for this specific monitoring and control task within the handling process for the bottle handling described is formed.
  • a meaningful control parameter can also be generated in the form of an information output via a graphical user interface, such information output being able to instruct the operator of the system to check the gripper head and, if necessary, repair defective gripper tulips within a short time Exchange time in order to be able to achieve the desired process quality again.
  • measured wear within such a gripper head which can be derived from a gradually or continuously increasing error value, can be used in the manner described above to predict the probability of failure of the affected gripper tulips.
  • the increasing wear measurement values provide, in particular, information about the remaining running time before a tolerable wear limit of the respective gripper tulip is reached. Modified maintenance cycles can then be generated from the forecast values in order to be able to avoid an actual failure of the gripper head with a high degree of reliability.
  • a further embodiment can provide that automated troubleshooting can be carried out using a suitable robot, an autonomous troubleshooting device or the like, possibly with the support of a driverless transport system (so-called AGV). In this case, it makes sense to generate control parameters that are able to appropriately control a robot programmed in this way or another suitable troubleshooting device and to control the automated troubleshooting.
  • AGV driverless transport system
  • this system is equipped with at least one system module with at least one sensor, which is intended and equipped in a way to sensorically detect at least one process parameter of the system in operation and to generate corresponding output signals that can be fed to further sensor data processing are.
  • At least one sensor of possibly several existing sensors can, for example, be assigned to a transport area or a handling module of the packaging system, while it can also make sense to assign a second sensor to another transport area or another handling module of the packaging system, with all sensor signals preferably being recorded equally and an evaluation with the aim of detecting and avoiding faulty process sequences and/or optimizing the system control.
  • This desired optimization of the system control by detecting and avoiding faulty process phases or individual processes can certainly be carried out iteratively, for example by detecting recurring errors and corresponding interventions at process-relevant points in the system or individual modules thereof.
  • the packaging system according to the invention or the system according to the invention and defined above for the production, filling, handling, packaging and / or conveying of containers can comprise a control unit, whereby this control unit can be designed to process the data of the first sensor and / or the second sensor to process, evaluate and compare and thereby to determine characteristic parameters of the conveying and / or processing processes taking place in the system and / or the articles or containers transported, treated, processed and possibly changed there win, again with the aim of being able to improve and optimize the processes carried out.
  • the sensors used can be formed, for example, by light barrier systems or by image processing systems of different types.
  • Suitable image processing systems are, for example, camera systems with downstream image evaluation, which can provide high-resolution sensor data to determine the process parameters of interest.
  • the system according to the invention for the production, filling, handling, packaging and/or conveying of containers can also be assigned a handling device or troubleshooting device with different modes of operation and/or design that can be controlled automatically and based on the determined and processed sensor data.
  • a handling device or troubleshooting device can, for example, be a stationary or mobile device that can be used at different positions along the system modules
  • a robot with a movable gripper arm can be formed, which is able to quickly eliminate many of the sensor-detected errors or blockages that can arise from containers that have fallen over or become jammed by removing the affected container.
  • Such a handling device or error elimination device can, for example, also be formed by a so-called AGV, i.e. by a driverless transport system or a driverless transport vehicle, on which a robot-like gripper arm can be mounted in order to eliminate or resolve the errors or blockages described.
  • AGV a so-called AGV
  • a driverless transport system or a driverless transport vehicle on which a robot-like gripper arm can be mounted in order to eliminate or resolve the errors or blockages described.
  • a removal device can be formed, for example, by a robot with a movable gripper arm, such a robot preferably being controllable in such a way that it grabs containers or container combinations that are recognized as defective, such as shrink-wrapped containers covered with foil, and transfers them to a reject container that is available for this purpose can.
  • the removal device is formed by a slide or the like, which slide is designed to be transversely movable to a transport direction of the containers, the container assemblies or, for example, the shrink packs within the packaging system, so that such a slide is designed to be defective Containers, container assemblies or shrink packs can be transferred to a reject container arranged next to a transport device for the shrink packs.
  • the system referred to here for the production, filling, handling, packaging and/or conveying of containers can also be generally referred to as a beverage processing machine.
  • a beverage processing machine can also be used for beverage production in general, for example in the case of a brewing system.
  • Such an individual module of a system according to the invention for the production, filling, handling, packaging and/or conveying of containers can be, for example, a degasser for beverages or beverage ingredients, a module for short-term heating, a so-called pasteurizer or even a module for the direct heating of beverages and/or or the container holding the drinks.
  • FIG. 1 For example, a buffer tank, a valve for beverage lines or several such valves for beverage lines or beverage-carrying pipelines.
  • a brewhouse of a brewing system can also be viewed as an individual module of a system according to the invention, as can a mash kettle, the separators of a brewing system, a wort kettle or other individual components.
  • Further system parts can be formed by homogenizers, heat exchangers, pumps, carbonizers, CIP systems and more.
  • conveying sections that are required for the connection of successive system modules are to be viewed as individual modules in the sense of the above definition, so that these conveying sections can also be monitored using sensors and any malfunctions that may occur can be remedied in an automated or semi-automated manner using suitable handling interventions.
  • Sensory monitoring devices include, for example, single-lane sensors that can detect any disruptions or congestion in container transport, regardless of the number of parallel transport or conveyor lanes.
  • the data from these sensors can be evaluated in the manner described and used to control the system modules mentioned, for example to reduce wear-related faults, but also to avoid faults that can be attributed to general component failure, human error or other causes.
  • Corresponding visualizations are generated, for example on a suitable display device, on an input terminal with an associated screen, etc., which is also usually referred to as a user interface (HMI - Human Machine Interface) with associated information display.
  • HMI Human Machine Interface
  • an operator or system operator can be provided with easily recognizable and quickly graspable information about the state of wear of the affected system modules or about the general condition of care, which allows him to assess the operational safety and reliability of the processes in progress Processes enabled or facilitated.
  • Such containers which are processed with a container treatment system according to the invention using the method according to the invention described here, are preferably closed containers with liquid or pasty products contained therein, in particular containers made of plastic, glass or metal. Particularly preferably, they can be beverage containers in the form of bottles or cans.
  • the container treatment system explained here as an example can preferably comprise at least a first system module, which is formed, for example, by a labeling module or the like, into which previously filled containers are conveyed by means of a container inlet in a defined transport direction in order to be labeled there.
  • a transport section with several parallel individual lanes, which are each separated from one another by lane plates that are spaced apart in a defined manner and are sensibly spaced apart from one another according to the container diameter, can lead in the transport direction to a second system module adjoining the first system module.
  • This second system module can be formed, for example, by a grouping station in which a defined number of containers are grouped in order to be packed in a subsequent third system module.
  • the third system module can be formed, for example, by a packaging station in which the previously grouped containers can be packaged in a suitable manner and further processed into packaging units, for example by equipping them with a packaging blank made of cardboard, by wrapping them with heat-shrinkable packaging film, by applying a strapping stretched around the containers or through the use of other packaging materials or outer packaging not mentioned here.
  • the third system module formed by the packaging station does not directly connect to the second system module formed by the grouping station, there can also be a further transport section between the two system modules on which the grouped containers are transported in the transport direction from the grouping station be transported to the packaging station. Additional system parts or modules can be connected to the third system module or the packaging station, for example for palletizing the packaging units previously formed in the packaging station.
  • the system is equipped with several sensors, each of which can be located in the transport section for sensory monitoring of the container transport within the transport lanes.
  • the sensors can be used to determine whether there are faults in the monitored system area, here within the individual transport lanes of the transport section.
  • the process parameter or parameters can be determined, for example, by means of optical sensors, whereby these optical sensors can advantageously be formed by cameras with downstream image evaluation assigned to the individual transport lanes of the defined transport section, in order to prevent jams caused by jammed or fallen containers within the individual transport lanes to recognize.
  • the sensors or cameras each deliver image signal data to a downstream evaluation device, which is responsible for data evaluation of the image signal data supplied.
  • the respectively determined process parameter can be stored in the evaluation device in the form of the image signal data supplied by the sensors or cameras and processed in a third method step by means of a data evaluation implemented there.
  • the stored values of the image signal data can be evaluated in particular with regard to a typical accumulation of deviations from defined target value ranges within defined time periods and/or in connection with previously made process modifications.
  • a number of exceeding or falling below the limit values specified by the respective target value ranges and / or an extent of the deviation from the respective one are determined
  • the setpoint range is determined in order to be able to recognize typical fault patterns and, if necessary, rectify them.
  • This control parameter can, for example, provide control data for an actuator, for an adjustment device or the like, with the help of which a process-influencing measure can be taken, such as an adjustment process for adjusting the width of the lane plates or another suitable measure.
  • the values or image signal data determined by sensors in the first method step which represent the at least one process parameter, are stored in a database within the evaluation device and continuously made available for data evaluation.
  • the error event defined in the fourth method step can therefore be derived at any time from the data evaluation, with different target values being specified and/or the permitted number of deviations from the respective target value range being varied as required.
  • a sensor-determined parameter value located within the predetermined setpoint range can be correlated with a section of the respective production, handling, packaging and/or conveying process that runs approximately smoothly.
  • This subsection can be formed, for example, by the transport section mentioned, which is located between the first system module and the second system module of the container treatment system.
  • an accumulation of exceedances of the setpoint range that remains below a predetermined limit value can be correlated with a subsection of the respective production, handling, packaging and / or conveying process that runs smoothly and meets predetermined quality requirements, this subsection being formed here by the transport section can be, but can also optionally represent other areas of the system.
  • the event defined in the fourth method step can be processed in different ways within the data evaluation of the evaluation device.
  • the control parameter mentioned is derived from the defined event in the form of an error event, which leads to a stopping of at least the affected section of the respective production, handling, packaging and / or conveying process or the entire process of the system. Stopping the process in its entirety can be particularly useful in the case of critical parameter deviations or excessive deviations that make it no longer sensible to continue the process, for example because profound disruptions are to be expected or the serious consequences of the disruption must first be eliminated before the process can start again . This can be the case, for example, due to a blockage in one of the transport lanes of the transport section that cannot be easily remedied, so that complete container groupings can no longer be formed within the grouping station.
  • At least one control parameter is derived from the defined event, from which process-influencing or process-changing control specifications for the method are formed.
  • control specifications can, in particular, initiate or bring about sensible corrections in the process flow, which can either contribute to maintaining the production, handling, packaging and/or conveying process in progress or to improving it, i.e. to a reduction in the influence of disruptions or the susceptibility to disruptions.
  • control parameters as control specifications for a removal robot that can remove a fallen or jammed container from the relevant transport lane and restore perfect transport in the transport direction within the previously faulty transport lane.
  • a control parameter is derived from the defined event in the form of an error event, which is at least stored and preferably visualized via a user interface such as a display device or the like or otherwise accessible to a user is made.
  • the error events can be processed and/or modified by the user in different ways before they are used as process-changing or process-influencing manipulated variables.
  • the fourth method step of the method is the further possibility of essentially not only detecting any process-influencing faults through sensory monitoring of the corresponding process sections and process phases, here for example the transport section mentioned, but also of these fault reports (e.g. image signal data).
  • the data evaluation can appropriately classify the faults that have occurred and are detected by sensors in the process flow and divide them into faults that occur due to wear or atypical faults. Depending on the classification made, different options for action are then available, which will be considered below using further exemplary embodiments.
  • the system can also have other elements and modules that have not been mentioned above, including a container feeder.
  • a container feed can, for example, include a mass flow area in which numerous containers are fed in the mass flow and pushed into first wide transport lanes in a first lane area, which can in particular form the first transport section mentioned several times above.
  • first wide transport lanes several containers can optionally be moved at least partially next to each other in the transport direction.
  • second aisle area the containers are pushed into parallel individual aisles, with the containers being transported in a row one behind the other in each individual aisle.
  • the first lane area and the second lane area preferably each include lane plates which separate the individual lanes from one another.
  • the lane plates are typically arranged hanging above a horizontal conveyor device, usefully in a parallel arrangement to one another.
  • the horizontal conveyor device can be formed, for example, by a conveyor belt or similar, which is suitable for the constant transport of containers in the transport direction.
  • the containers which are now arranged in parallel rows, are then fed via a discharge area for further processing, for example the packaging of groups of containers within a film wrapping module or similar.
  • the discharge area can therefore optionally also correspond to the further transport section, which is the Containers are transported to a packaging station in the system and process variant described above.
  • the position of the containers is detected directly in the inlet frame of the subsequent packaging module or in the inlet frame of the discharge area or the further transport section to the subsequent packaging module or at another suitable location, preferably by means of optical sensors.
  • This sensory detection can optionally be carried out by vertically acting distance sensors, which can each form the optical sensors.
  • individual distance sensors each work with light beams acting vertically downwards, which interact with the containers transported underneath.
  • the image signal data determined by the optical sensors or the distance sensors in the first method step are transmitted in the second method step to the evaluation device, which at the same time forms a control unit.
  • the evaluation device or control unit assigns a determined fault to a respective individual aisle.
  • the determined data or process parameters can in particular be stored in a database assigned to the evaluation device and continuously made available to the previously explained data evaluation by the evaluation device or the control unit referred to here.
  • the evaluation of the image signal data transmitted from the plurality of distance sensors to the evaluation device it is recorded in particular when a disruptive event occurs frequently in a specific individual lane or in one of the transport lanes. As has already been explained before, one reason for this can be found, for example, in an incorrect setting of the aisle width due to incorrect positioning of the aisle plates.
  • information is generated as an event that provides an indication that the aisle setting of a specific individual aisle needs to be checked.
  • the event is derived from the data evaluation.
  • an output is carried out on a display device, which can optionally be equipped with a graphical user interface or similar, in order to display the data for one Visualize users and allow user input.
  • the information can also be coupled with an acoustic signal output.
  • a recommendation can be issued to check the settings within the container treatment system more closely.
  • a recommendation is issued to the user by means of the display device and the graphical user interface as to which areas within the container treatment system and/or which settings should be checked in more detail and at which point.
  • information is generated as an event that provides an indication that the components within the specific individual aisle are being checked and, if necessary, must be replaced.
  • the data collected in the evaluation device and analyzed by means of data evaluation can also be used to optimize the design, in particular by comparing it with a database that provides predefined settings.
  • Fig. 1A shows a highly schematic representation of a conceivable embodiment variant of a system section of a system according to the invention for the production, filling, handling, packaging and / or conveying of containers.
  • Fig. 1 B shows a block diagram which schematically represents the process steps of a method for controlling production, handling, packaging and/or conveying processes of containers.
  • Fig. 2 shows a schematic view from above of a container feed of a further embodiment variant of a container treatment system.
  • Fig. 3 shows a perspective view of a partial area of the container feed according to Fig. 2.
  • Fig. 4 shows an embodiment of the use of the method schematically illustrated and described above in Fig. 1B.
  • FIG. 1A illustrates an exemplary embodiment of a system, marked here with the reference number 10, for the production, filling, handling, packaging and / or conveying of containers with liquid or pasty products contained therein.
  • This system is also referred to as container treatment system 10 in the following description.
  • FIG. 1 B illustrates successive method steps 101, 102, 103 and 104 of a method 100 for controlling production, handling, packaging and/or conveying processes of containers with liquid or pasty products contained therein, in particular in connection with operation a system 10 according to FIG. 1A.
  • a system 10 according to FIG. 1A.
  • the containers that are processed with the container treatment system 10 according to the invention using the method 100 are preferably closed containers with liquid or pasty products contained therein, in particular containers made of plastic, glass or metal. They are particularly preferably beverage containers in the form of bottles or cans.
  • the container treatment system 10 can comprise a first system module 12, which is formed, for example, by a labeling module 14 or the like, into which previously filled containers are placed by means of a container inlet 16 in the transport direction TR (in FIG. 1A from left to right according to the direction of the arrow) in order to be labeled there.
  • This second system module 24 can be formed, for example, by a grouping station 26, in which a defined number of containers 28, which are each indicated schematically in the transport lanes 20, are grouped in order to be packed in a subsequent third system module 30.
  • the third system module 30, which is only indicated here can be formed, for example, by a packaging station 32, where the previously grouped containers 28 can be packaged in a suitable manner and further processed into packaging units, for example by equipping them with a packaging blank made of cardboard, by wrapping them with shrinkable ones under the influence of heat Packaging film, by applying a strapping stretched around the containers 28 or by using other packaging materials or outer packaging not mentioned here.
  • the third system module 30 formed by the packaging station 32 does not directly connect to the second system module 24 formed by the grouping station 26, there can also be a further transport section 34 between the two system modules 24 and 30, on which the grouped containers 28 can be transported in the transport direction TR be transported from the grouping station 26 to the packaging station 32.
  • Additional system parts or modules can be connected to the third system module 30 or the packaging station 32, for example for palletizing the packaging units previously formed in the packaging station 32, but this is not shown in more detail here, since it is only a schematic representation of some modules that are to be understood as examples a container treatment plant 10 should act.
  • Fig. 1A several sensors 36 can be seen, each of which is arranged in the transport section 18 for sensory monitoring of the container transport within the transport lanes 20.
  • the sensors 36 are used in a first method step 101 to determine whether there are faults in the monitored system area, here within the individual transport lanes 20 of the transport section 18.
  • This process parameter determined in the first method step 101 which relates to the proper transport of the Container 28 within the transport section 18, can be recorded continuously or cyclically at recurring time intervals.
  • the process parameter or parameters can be determined, for example, by means of optical sensors 36, whereby these optical sensors 36 can advantageously be formed by cameras 38 assigned to the individual transport lanes 20 of the transport section 18 with downstream image evaluation, in order to prevent jams caused by jammed or fallen containers 28 can be seen within the individual transport lanes 20.
  • the sensors 36 or cameras 38 each deliver image signal data 40 to a downstream evaluation device 42, which is responsible for the data evaluation of the image signal data 40 supplied.
  • the stored values of the image signal data 40 are analyzed with regard to a typical accumulation of deviations from defined target value ranges within defined time periods and/or or evaluated in connection with previously made process modifications.
  • a number of detected overshoots or undershoots of the limit values specified by the respective setpoint ranges and/or an extent of deviation from the respective setpoint range is determined in order to be able to recognize and, if necessary, correct typical fault patterns .
  • a fourth method step 104 an event is defined in a fourth method step 104 and from this a control parameter PM for process-influencing or process-changing control specifications generated in procedure 100.
  • This control parameter PM is shown in the schematic representation of FIG. 1A as a data arrow that leads out of the evaluation device 42 and leads to the transport section 18, since it is there Can provide control data for an actuator (not shown here), for an adjusting device or the like, with the help of which a process-influencing measure can be taken, such as an adjustment process for adjusting the width of the lane plates 22 or another suitable measure.
  • the values or image signal data 40 determined by sensors in the first method step 101 which represent the at least one process parameter, are stored in a database within the evaluation device 42 and are continuously made available to the data evaluation 44.
  • the error event defined in FIG. 1 B in the fourth method step 104 can thus be derived at any time from the data evaluation 44, with different target values being specified and/or the permitted number of deviations from the respective target value range being varied as required.
  • this subsection can be formed, for example, by the transport section 18, which is located between the first system module 12 and the second system module 24 of the container treatment system 10.
  • an accumulation of exceedances of the setpoint range that remains below a predetermined limit value can be correlated with a section of the respective production, handling, packaging and / or conveying process that runs smoothly and meets specified quality requirements, this section being here through the transport section 18 is formed, but can optionally also represent other areas of the system 10.
  • the processing of the event defined in the fourth method step 104 within the data evaluation 44 of the evaluation device 42 can take place in different ways.
  • the control parameter PM mentioned is derived from the defined event in the form of an error event, which leads to a stopping of at least the affected section of the respective production, handling, packaging and / or conveying process or the entire process of system 10. Stopping the process in its entirety can be particularly useful in the case of critical parameter deviations or excessive deviations that make it no longer sensible to continue the process, for example because profound disruptions are to be expected or the serious consequences of the disruption must first be eliminated before the process can start again . This can be the case, for example, due to a blockage in one of the transport lanes 20 of the transport section 18 that cannot be easily remedied, so that complete container groupings can no longer be formed within the grouping station 26.
  • At least one control parameter PM is derived from the defined event, from which process-influencing or process-changing control specifications for the method 100 are formed.
  • control specifications can in particular initiate or bring about sensible corrections in the process flow, which can either contribute to maintaining the production, handling, packaging and/or conveying process in progress or to its improvement, i.e. to a reduction in the influence of disruptions or the susceptibility to disruptions.
  • control parameters PM as control specifications for a removal robot (not shown here), which removes a fallen or jammed container 28 from the relevant transport lane 20 and ensures perfect transport in the transport direction TR within the previously faulty transport lane 20 can restore.
  • a control parameter PM is derived from the defined event in the form of an error event, which is at least stored and preferably visualized via a user interface such as a display device 46 or the like or in some other way is made accessible to a user.
  • the error events can be processed and/or modified by the user in different ways before they are used, if necessary, as process-changing or process-influencing manipulated variables.
  • This alternative or additional option is indicated in FIG. 1A by the broken data arrow between the evaluation device 42 and the display device 46.
  • the data evaluation 44 can suitably classify the disturbances that have occurred and are detected by sensors in the process flow and divide them into disturbances that occur due to wear or into atypical disturbances. Depending on the classification made, different options for action are then available, which will be considered below using further exemplary embodiments.
  • FIG. 2 shows a system section with a container feed 16 of a container treatment system 10, which, however, has different elements and modules than the system 10 previously shown in Fig. 1A.
  • Fig. 3 shows a perspective view of a partial area of the container feed 16 according to Fig. 2.
  • the container feed 16 comprises a mass flow area 48, in which the containers 28 (see FIG. 1 A), which cannot be seen here, are fed in the mass flow and pushed into first wide transport lanes 20 in a first lane area 50, which here forms the first transport section 18 .
  • first wide transport lanes 20 Within the first wide transport lanes 20, several containers 28 are moved at least partially side by side in the transport direction TR.
  • second lane area 52 the containers are pushed into parallel individual lanes 54, with the containers 28 being transported in a row one behind the other in each individual lane 54.
  • the first lane area 20 and the second lane area 52 each include lane plates 22 which separate the individual lanes 20 and 52 from one another.
  • the lane plates 22 are arranged hanging above a horizontal conveyor device 56, sensibly in a parallel arrangement to one another.
  • the horizontal conveyor device 56 which is only indicated schematically here, can be formed, for example, by a conveyor belt or the like, which is suitable for the constant transport of containers in the transport direction TR, which runs from left to right in the graphic representation of FIG At the top left it flows into system 10 and then points to the right.
  • the containers 28, which are now arranged in parallel rows, are then fed via a removal area 58 for further processing, for example the packaging of groups of containers within a film wrapping module or similar.
  • the removal area 58 which is on the far right in the graphical plan view of FIG is located, optionally also correspond to the further transport section 34, which transports the containers 28 in the variant according to FIG. 1A to a packaging station 32.
  • the position of the containers 28 is detected directly in the inlet frame of the subsequent packaging module 32 (see FIG. 1A) or according to FIG Sensors 36.
  • this sensory detection is carried out by vertically acting distance sensors 60, which each form the optical sensors 36 (see FIG. 1A).
  • individual distance sensors 60 each work with light beams acting vertically downwards, which interact with the containers 28 transported underneath.
  • Such a light beam from a distance sensor 60 is shown by an arrow in the schematic perspective view of FIG. 3.
  • the further light beams from the remaining distance sensors 60 would be identified by parallel arrows, which, however, have been omitted in the interests of better clarity of the illustration.
  • the image signal data 40 (see FIG. 1 A) determined by the optical sensors 36 or the distance sensors 60 as part of the first method step 101 (see FIG. 1B) are sent to the evaluation device 42 in the second method step 102 illustrated in FIG. 1 B transmitted, which at the same time forms a control unit.
  • the evaluation device 42 or control unit assigns a determined fault to a respective individual lane 54 as part of the third method step 103 (see FIG. 1 B).
  • the determined data or process parameters can in particular be stored in a database assigned to the evaluation device 42 and continuously made available to the previously explained data evaluation 44 by the evaluation device 42 or the control unit referred to here.
  • the image signal data 40 transmitted from the plurality of distance sensors 60 to the evaluation device 42 is recorded in particular when a disruptive event occurs in a specific individual alley 54 (see FIG. 3) or in one of the Transport lanes 20 (see FIG. 1A) occur frequently. As has already been explained previously, one reason for this can be found, for example, in an incorrect setting of the lane width due to incorrect positioning of the lane plates 22.
  • information is generated as an event that provides an indication that the aisle setting of a specific individual aisle 54 or 20 needs to be checked.
  • the event is derived from the data evaluation 44.
  • an output is made on a display device 46, which can optionally be equipped with a graphical user interface 62 or similar in order to be able to visualize the data for a user and to allow the user to make user input.
  • the information can also be coupled with an acoustic signal output.
  • a recommendation can be issued to check the settings within the container treatment system 10 more closely.
  • a recommendation is issued to the user by means of the display device 46 and the graphical user interface 62 as to which areas within the container treatment system 10 and/or which settings should be checked in more detail at which point.
  • the error messages relating to a specific lane 20 or 54 noticeably accumulate over a longer period of operation.
  • Such a noticeable accumulation can indicate wear on a component within this alley 20 or 54, for example wear on an alley plate 22 or on rollers of a roller conveyor belt or the mat chain within the alley area 50, so that a defective or faulty horizontal conveyor 56 can be concluded can be.
  • information is generated as an event that provides an indication that the components within the specific individual aisle 20 or 54 are being checked and, if necessary, must be replaced.
  • the data collected in the evaluation device 42 and analyzed using the data evaluation 44 can also be used to optimize the design, in particular by comparing it with a database that provides predefined settings.
  • FIG. 4 illustrates an embodiment of the use of the above-described method 100, which was already shown with reference to FIG. 1B.
  • the time plotted and measured from the times t(0) to t(1) in the vertical direction from top to bottom represents a predefined period of time.
  • various process parameters are detected by sensors in the manner described, stored continuously or cyclically at recurring time intervals and processed by means of a data evaluation 44 (cf. FIG. 1A and FIG. 3). From this, events are defined in the form of error messages “Error 1”, “Error 2” and “Error 3” and displayed on a graphical user interface 62.
  • each error message is assigned a priority. If an error occurs a first time within the predefined time period between t(0) and t(1), then this error receives priority 1. If the error occurs a second time within the predefined time period, then it receives priority 2. At The third occurrence within the predefined time period between t(0) and t(1), the priority increases to 3, which can be continued with further priority levels.
  • Each error message (Error 1, Error 2, Error 3) can also be assigned an additional weighting. It can be the case that error message 3 in connection with a priority 3 triggers an automated error correction, while, for example, an error message 1 in connection with a priority 2 already triggers an alarm message, for example a wear warning, an instruction for a functional test or similar can.
  • t(0) to t(1) i.e. a period of time totaling 24 hours
  • this day also being divided into three shifts S1 to S3, each of these shifts being S1, S2 and S3 each last eight hours.
  • the additional prioritization allows an accumulation of certain error messages to be detected more quickly.
  • packaging module 32 packaging station, packaging module

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  • Engineering & Computer Science (AREA)
  • General Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Quality & Reliability (AREA)
  • Physics & Mathematics (AREA)
  • General Physics & Mathematics (AREA)
  • Automation & Control Theory (AREA)
  • Control Of Conveyors (AREA)

Abstract

L'invention concerne : un procédé (100) de commande de processus de production, de manipulation, d'emballage et/ou de transport de récipients (28) contenant des produits liquides ou pâteux ; et un système de traitement de récipients (10) pour la production, le remplissage, la manipulation, l'emballage et/ou le transport de tels récipients (28). Dans le système (10) et dans le procédé (100), des capteurs sont utilisés pour déterminer au moins un paramètre du processus qui indique un défaut dans au moins une partie des processus. À cet effet, les valeurs déterminées par le capteur du ou des paramètres de processus sont stockées de manière continue ou cyclique à des intervalles de temps récurrents et traitées au moyen d'un processus d'évaluation de données (44), dans lequel les valeurs stockées sont analysées pour déterminer un ensemble d'écarts par rapport à des plages de valeurs cibles définies dans des périodes définies et/ou en liaison avec des modifications de processus exécutées précédemment. En outre, un nombre de cas identifiés de dépassement ou d'insuffisance des valeurs limites spécifiées par les plages de valeurs cibles pertinentes et/ou une étendue de l'écart par rapport à la plage de valeurs cibles pertinente sont déterminés. Un événement d'erreur est établi si un nombre défini d'écarts par rapport à la plage de valeurs cibles pertinente est dépassé ou si un écart par rapport à la plage de valeurs cibles pertinente dépasse une certaine ampleur, ou en cas de combinaison des écarts susmentionnés, et cet événement d'erreur est utilisé pour générer un paramètre de commande (PM) pour des spécifications de commande d'influence ou de modification du processus dans le cadre du procédé (100).
PCT/EP2023/065746 2022-09-06 2023-06-13 Procédé de commande de processus de traitement de récipients et système de traitement de récipients pour la production, le remplissage, la manipulation, l'emballage et/ou le transport de récipients WO2024051976A1 (fr)

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DE102022122554.2A DE102022122554A1 (de) 2022-09-06 2022-09-06 Verfahren zur Steuerung von Prozessen des Behälterhandlings und Behälterbehandlungsanlage zur Produktion, Abfüllung, Handhabung, Verpackung und/oder Förderung von Behältern
DE102022122554.2 2022-09-06

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Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE10209154A1 (de) * 2002-03-01 2003-09-11 Sig Cantec Gmbh & Co Kg Vorrichtung zum Umformen und/oder Falzen von Dosenzargen
DE102016107407A1 (de) * 2015-11-03 2017-05-04 Festo Ag & Co. Kg Applikationsbasierte Steuerung einer Ventilscheibe
DE102020120336A1 (de) 2020-07-31 2022-02-03 Krones Aktiengesellschaft Transportvorrichtung und Verfahren zur Verteilung einer Vielzahl gleichartig geformter und dimensionierter Artikel
DE102020121890A1 (de) * 2020-08-20 2022-02-24 Samson Aktiengesellschaft Verfahren zur Diagnose eines Steuer- und/oder Regelungssystems sowie Steuer- und/oder Regelungssystem

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Publication number Priority date Publication date Assignee Title
GB0415951D0 (en) 2004-07-16 2004-08-18 Meadwestvaco Packaging Systems A method for identifying abnormal operation of a machine and an apparatus therefor
DE102011017448A1 (de) 2011-04-18 2012-10-18 Krones Aktiengesellschaft Verfahren zum Betreiben einer Behältnisbehandlungsanlage mit Störungsdiagnose
DE102013208355A1 (de) 2013-05-07 2014-11-13 Krones Ag Vorrichtung und Verfahren zur Aufbringung einer Etikettenhülse
EP2808291A1 (fr) 2013-05-31 2014-12-03 Sidel S.p.a. Con Socio Unico Système et procédé de maintenance prédictif pour une machine de remplissage

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE10209154A1 (de) * 2002-03-01 2003-09-11 Sig Cantec Gmbh & Co Kg Vorrichtung zum Umformen und/oder Falzen von Dosenzargen
DE102016107407A1 (de) * 2015-11-03 2017-05-04 Festo Ag & Co. Kg Applikationsbasierte Steuerung einer Ventilscheibe
DE102020120336A1 (de) 2020-07-31 2022-02-03 Krones Aktiengesellschaft Transportvorrichtung und Verfahren zur Verteilung einer Vielzahl gleichartig geformter und dimensionierter Artikel
DE102020121890A1 (de) * 2020-08-20 2022-02-24 Samson Aktiengesellschaft Verfahren zur Diagnose eines Steuer- und/oder Regelungssystems sowie Steuer- und/oder Regelungssystem

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