Production line with adaptive line control and processes

Abstract

Production line (A, B), configured as a packaging line (1) or a dough processing line (9), comprising a plurality of line modules (I - VI) arranged one behind the other in the production direction (R), and a line control unit (8) functionally connected to the line modules (I - VI), by means of which the line modules (I - VI) can be controlled, wherein a software configuration (K) of the line control unit (8) depends on reports (R) received by it and sent by the line modules (I - VI), defining their respective functional scope. I - VI) is adaptable, characterized in that by adapting the software configuration (K) of the line control (8) a user interface provided for the line control (8) can be adapted, in that when starting up the line modules (I - VI) currently used in the production line (A, B) into a standby mode at least one operating terminal used along the production line (A, B) adds or reduces buttons of the line control (8) that can be called up therein with regard to the available functional scopes of the line modules (I - VI), in order to only display to a production employee the buttons in the line control (8) by means of which the line modules (I - VI) used in the production line (A, B) can be controlled.

Description

[0001] The present invention relates to a production line with an adaptive line control according to claim 1 and further relates to a corresponding method according to independent method claim 11.

[0002] In production lines, such as packaging lines or dough processing lines, where several machines configured as line modules for specific purposes are arranged one behind the other in the direction of production, it is possible that the respective line modules are used with different software versions and / or control components in the production line. Therefore, the line modules may have different functional scopes in both the software and hardware configuration. This makes it difficult to configure a line control system specifically for the production line, i.e.a control system by means of which several line modules can be controlled together, for example started or stopped together, with regard to the different functional scopes available on them, so that it can be used with maximum functionality even if the software or hardware configuration of the production line changes.

[0003] DE 10 2004 023 498 A1 discloses a device for electronically controlling or regulating transfer lines, which are used, for example, for large-scale production. This transfer line uses a central computer as a system monitor, which is equipped with a line editor. This allows graphical output and editing of all information and programs relating to the transfer line or production system.

[0004] DE 10 2016 009 406 A1 discloses a packaging machine assembled from several machine modules. A main control program used on this packaging machine depends on the control subprograms the respective machine modules are to operate with. A central computing device is used to generate the main control program from the respective control subprograms of the machine modules used.

[0005] The object of the invention is to provide an advantageous line control system for a production line for controlling the line modules used in the production line.

[0006] This object is achieved by the technical features of claim 1 and by a method according to independent claim 11.

[0007] Advantageous further developments of the invention are given by the respective subject matters of the subclaims.

[0008] The production line according to the invention, which is configured in the form of a packaging line or a dough processing line, comprises a plurality of line modules arranged one behind the other in the production direction, as well as a line control system functionally connected to the line modules, by means of which the line modules can be controlled, for example, jointly to start up into a standby mode. The production line according to the invention provides that a software-side configuration of the line control system can be adapted depending on reports received by it and sent by the line modules, in particular when starting up into standby mode, which define their respective functional scope. The invention executes a settings event, whereby the line control system for the line modules used within the production line is adjusted based on their functional scopes, in particular depending on their respective software versions, i.e.adapts to their software and / or hardware scope. The line control system thus coordinates its own software-based functionality with the existing software and / or hardware versions of the line modules used in the production line.

[0009] This allows the software functionality of the line control to be optimally adjusted, for example immediately when booting the respective line modules into standby mode, in view of the respective functional scopes of the line modules, so that, depending on the line modules actually used, i.e. on the basis of their respective software and / or hardware versions, software-based downward compatibility is achieved for them together by means of the line control. The line control according to the invention can therefore provide at least those functions which can also be supported by all line modules. This means that the line control remains cross-line, i.e. both downwardly oriented with regard to the respective functional scopes of the line modules and with regard to the respective functional scopes of the line modules among themselves, i.e. horizontally oriented, with regard to their functional scopes.The line control is therefore at least two-dimensionally compatible in view of the software and / or hardware-based production line architecture.

[0010] Preferably, the software configuration of the line control system is adaptable depending on the reports it receives, which are sent by the line modules when they start up into standby mode and which define their respective functional scope. In particular, the line control system can be used to control the line modules for a joint start into standby mode. The line control system is updated, in particular, via a settings event that is automatically triggered in the line control system when the line modules start up. This ensures that the line control system is optimally tailored to the line modules used within the production line before the production line is started for manufacturing operation. This also makes it possible, in particular, to adapt the functional scope of the line control system when the line modules start up with regard to new software and / or hardware used within the production line.The line control system thus automatically initiates a possible upgrade with regard to a newly composed software and / or hardware production line architecture.

[0011] One variant provides for the line control to have a settings event function through which the software configuration of the line control can be adapted depending on reports received by the line modules upon activation of the settings event function and which define their respective functional scope. It would be conceivable for the settings event function to be callable within the line control by manual operation, e.g. by pressing a button. This function is available to the production employee at any time, i.e. it can be called by them regardless of the mode of the production line, even when it is switched off. It would be useful if predetermined intervals for carrying out the settings event could be set in the line control using the settings event function.Ideally, by adapting the software configuration of the line control system, only those functions supported by all line modules used in the production line are available. This means that the line control system only offers production line control functions that are actually supported by all line modules. This allows maximum utilization of the line control system across all lines, i.e., consistently for all line modules integrated in the production line.

[0012] One variant provides that the functional scopes of the line modules sent in the respective reports include information regarding the software versions used in the line modules and / or the hardware components installed therein, in particular control components and / or tools. This information can be temporarily stored for the line control system at least for a production project carried out following the startup of the line modules using the production line and remains stored at least until this project is considered completed. From this point on, the functional scope of the line control system can be adapted for a new project, for example, depending on other tools installed during a conversion process within the production line.This makes it possible to continually compare the functional scope of the line control with the current line module configuration on a project-by-project basis, provided there are changes in the production line architecture.

[0013] The invention provides that a user interface provided for the line control can be adapted by adapting the software configuration of the line control. The invention provides that when the line modules currently used in the production line are booted into standby mode, the settings event of the line control causes at least one operating terminal used along the production line to supplement or reduce the buttons of the line control that can be called up therein with regard to the existing functional scope of the line modules, in order to show the production employee only those buttons in the line control that can be used to control the line modules used in the production line. The buttons of the line control can thus be reduced or expanded to match the functional scope possible using the production line, thereby making operation of the production line clearer for the production employee.

[0014] According to one embodiment of the invention, a range of line items that can be called up using the line control can be changed depending on the adapted software configuration of the line control. This ensures that a large number of different items that can potentially be produced using the production line can be determined, in particular displayed, based on the current assembly of the production line. The software and / or hardware configuration used on the respective line modules can thus be used to functionally assign the line control only to the line items that can actually be produced together with it, in particular to product parameter recipes predetermined for this purpose, whereby the line control simultaneously provides the production employee with a feasibility overview of the line items that can be produced using the production line.Based on the range of line items that can be produced across lines, the line control system can show the production employee which changeover process would be necessary to produce a line item that is not included in the range.

[0015] An advantageous variant provides for the line control system to include a recipe suggestion function for line items that can be executed using the adapted line control system. The functionality of the recipe suggestion function depends on the status of the software configuration of the line control system. This recipe suggestion function can be used to optimally adjust process parameters for the respective line modules. The respective recipe variables suggested for this function can preferably be manually adjusted by the production employee via the line control system.

[0016] It would be advantageous if the line control system could update the software versions of the respective line modules. This can be done, for example, via an internet connection, in particular via a web-based application, such as a cloud-based application. Updating the respective software versions of the line modules automatically results in these being taken into account as the basis for adapting the software configuration of the line control system during the inventive settings event, for example, the next time the line modules are booted into standby mode. As a result, the line control system updates its functionality accordingly based on the adapted, updated software versions of the line modules.

[0017] In particular, it is possible for the software configuration of the line control system to be updated depending on data received at the line control system from an ERP, MES, MRP, and / or PPS system functionally connected to it. This makes it possible to integrate the production line into an extended production management system in such a way that the software configuration of the line control system can be adapted not only internally to the respective line modules within the production line, but also externally to the production environment of the production line. This can be described as three-dimensional adaptability of the line control system.

[0018] Above all, it is conceivable that the recipe parameters within the line control system, which can be accessed via the recipe suggestion function, can be adapted in real time based on the (inventory) data provided by the ERP, MES, MRP, and / or PPS system, in order to achieve a continuous production flow through the correspondingly adapted line control system. This advanced, software-based adaptation of the line control system thus enables a comparison between the production volume that is fundamentally feasible based on the production line and the material stocks available for this purpose.

[0019] It would be useful if the line controller were configured to send requests to the respective line modules based on the reports it receives, allowing settings for various functions to be activated on the respective line modules. These requests can, in particular, take into account the data received from the ERP, MES, MRP, and / or PPS system. This bidirectional communication takes place primarily via MQTT communication established between the modules and the line controller.

[0020] It would be possible to provide the respective requests sent to the line modules by the line control with information regarding the settings of the line modules in such a way that these can be controlled by means of a separate control outside of the line control, i.e. individually as such, only in accordance with the functional scope of the line control adapted by the Settings event. On a line module, using a module control provided for this purpose, only those functions can be controlled that are also compatible with the other line modules in line mode. This can prevent a production employee from assigning process parameters to the line modules as such that are not possible with the adapted line control, i.e. taking into account the use of all line modules of the production line.

[0021] The invention further relates to a method for setting an adaptive line control system for a production line consisting of several line modules, which is in the form of a packaging line or dough processing line. In the method according to the invention, particularly when the line modules are started up into a standby mode, a software-based configuration of the line control system is adapted depending on reports received by the line modules and defining their respective functional scope.

[0022] Preferably, when the line modules are booted into standby mode, the software configuration of the line control system is adapted based on the reports received by the line modules during booting into standby mode, which define their respective functional scope. This adapts the line control system, which can be called for the joint control of the line modules, to the respective functional scopes provided by the line modules before the line modules are started to execute a work order.

[0023] According to one embodiment of the invention, by activating a settings event function provided in the line control system, the software configuration of the line control system is adapted depending on the reports received by the line modules in response to the activation of the settings event function, which define their respective functional scope. For this purpose, for example, a button in the line control system can be activated regardless of the mode in which the production line is located.

[0024] The invention is explained with reference to the embodiments shown in the following figures. Fig. 1 a production line in the form of a packaging line, Fig. 2 a production line in the form of a dough processing line, and Fig. 3 a schematic representation of an adaptive line control for a production line.

[0025] Technical components are provided with the same reference symbols throughout the figures.

[0026] Fig. 1 shows a production line A configured as a packaging line 1. The Fig. The production line A shown in Figure 1 comprises several line modules I - V arranged one behind the other in the production direction R, which form various work machines used within the production line A. Line module I is a slicing device 2, by means of which, for example, sausage bars can be sliced. The slicing device 2 comprises an operating terminal T. I, which is equipped with a software configuration or software version x to control the processes of the slicing device 2. Downstream in the production direction R, a feeding device 3 is integrated as a second line module II in the production line A. This feeding device 3 is designed to transfer and / or group the products cut by the slicing device 2 into transport lanes. These processes can be carried out on the feeding device 3 by means of an operating terminal T provided thereon. II which is also equipped with software version x.

[0027] Further downstream in the production direction R, i.e. behind the feed device 3, a picking device 4 is provided as line module III in the production line A. The picking device 4 is configured to place the cut products provided in a predetermined format into tray parts provided within the picking device 4 in order to form tray parts filled to the desired weight. The picking device 4 has two operating terminals T III , each equipped with a software version z, which is fully compatible with the software version x. This extended software version z of the two operator terminals T III is therefore fully compatible with the software version x of the respective operator terminals T I , T II the slicing device 2 and the feeding device 3.

[0028] In the production direction R, following the picker device 4, a weighing device 5 follows as line module IV, by means of which the tray parts filled by the picker device 4 can be checked for a predetermined target weight. The weighing device 5 has an operating terminal T IV with a more advanced software version r than software version z. The advanced software version r is fully compatible with the previously mentioned software versions x and z.

[0029] At the end of the Fig. In the production line A shown in Figure 1, a packaging machine 6 is positioned as line module V, which is configured as a tray sealing machine to seal the provided tray parts filled with product. The packaging machine 6 has an operating terminal T Vwith a software version y installed therein, which represents a genuine software extension compared to the previously mentioned software versions r, x, z, and is therefore fully compatible with these software versions r, x, z.

[0030] The respective line modules I - V from Fig. 1 are connected via an MQTT communication 7. This MQTT connection established between the line modules I - V allows the line modules I - V to exchange their respective software versions r, x, y, z with each other to a control terminal T I - V to communicate with the callable line control 8. The line control 8 is designed to generate its own software configuration K depending on the reports R received by it and sent by the line modules I - V, which define their respective functional scope. I - V This adjustment of line control 8 with regard to the reports R received at it I - Vcan occur when the respective line modules I - V are started up in standby mode. Starting up line modules I - V in standby mode triggers a settings event of line control 8 so that it can be adapted for the line modules I - V actually used in production line A with regard to their software versions r, x, y, z.

[0031] The schematically shown in Fig. The line control 8 shown in Figure 1 can be used in particular on all operating terminals T used in the production line A I - V to functionally control the line modules I - V together, for example to start them up in standby mode at the same time, to start them for production at the same time, to stop them at the same time and / or to select a line article for them, whereby the respective line modules I - V can be pre-assigned with corresponding process parameters.

[0032] Fig. 1 shows schematically that in the line control 8 based on the received reports R I - V The software configuration K of the line control 8 is adapted to the software version x, which is supported by all line modules I - V. This ensures that the software configuration K of the line control 8 provides exactly the features that are consistently supported by the line modules I - V.

[0033] The line control 8 from Fig. 1 has a settings event function S that can be called manually by a production employee to update the software configuration K of the line control 8.

[0034] Fig. 2 shows a production line B, which is present as dough processing line 9. The dough processing line 9 from Fig. 2 has a total of six line modules I - VI in production direction R, whose respective operating terminals T I-VI communicate via an MQTT connection established between them. A software-based configuration of the T I-VI The line control of the dough processing line 9 is analogous to the line control 8 from Fig. 1 in particular based on the reports R sent by the respective line modules I - VI during startup I - VI customizable.

[0035] In Fig. 2, line module I is present as a dough storage device 10. Following this, a dough sheet forming device 11 is positioned as line module II. Line module III forms a dough portioning device 12 for forming dough portions from the provided dough sheet or from traces thereof. Further downstream in the production direction R, in the dough processing line 9, there is a forming device 13 as line module IV, by means of which provided portions can be brought into a predetermined shape. Further downstream, there is a topping device 14 as line module V, by means of which formed dough blanks can be covered or sprinkled with a product. At the end of the dough processing line 9 of production line B, there is a baking device 14 as line module VI for bringing the provided products to a desired temperature level.

[0036] At the respective line modules I - VI from the Fig. 1 and Fig. 2 shown production lines A, B, hardware components used there and / or on the operating terminals T I-VI Expand the installed software versions, preferably to ensure they are fully compatible with each other. The respective software versions of line modules I - VI form the basis for adapting the software-side configuration K of line control 8 when the respective line modules I - VI are booted into standby mode.

[0037] Fig. Figure 3 illustrates in a schematic representation the functional principle of the line control 8, which is adaptive with respect to different software versions x, y, z, q. For the software-side configuration K of the line control 8, there is a vertical downward compatibility V as well as a horizontal compatibility H between the line modules I - IV, based on which the software-side configuration K of the line control 8 is adaptable with regard to the line modules I - IV actually used. Furthermore, Fig. 3 a further compatibility P, which results, for example, from a functional connection of the line control 8 with an ERP, MES, MRP and / or PPS system.

[0038] Furthermore, Fig. 3 in a schematic representation that the line control 8 except for receiving the respective reports R I- IV also for sending corresponding requests Q I - IVto the respective line modules I - IV in order to assign process parameters to the respective control programs used on the line modules I - IV with regard to the software configuration K.

[0039] Fig. 3 thus shows in a schematic representation that the line control 8 of the production line A, B is software compatible in several directions H, V, P in view of the respective line modules I - IV used in the production line A, B in order to be able to offer a production employee a range of functions for the line control 8 that is tailored to the line modules I - IV used.

Claims

[1] Production line (A, B) which is configured in the form of a packaging line (1) or a dough processing line (9), comprising a plurality of line modules (I - VI) arranged one behind the other in the production direction (R) and a line control (8) which is functionally connected to the line modules (I - VI) and by means of which the line modules (I - VI) can be controlled, wherein a software-side configuration (K) of the line control (8) is determined as a function of reports (R) received by the line modules (I - VI) and defining their respective functional scope. I - VI ) is customizable, characterized bythat by adapting the software-side configuration (K) of the line control (8), a user interface provided for the line control (8) can be adapted in that, when the line modules (I - VI) currently used in the production line (A, B) are started up into a standby mode, at least one operating terminal used along the production line (A, B) supplements or reduces buttons of the line control (8) that can be called up therein with regard to the existing functional scopes of the line modules (I - VI), in order to show a production employee only the buttons in the line control (8) by means of which the line modules (I - VI) used in the production line (A, B) can be controlled. [2] Production line according to claim 1, characterized bythat the software-side configuration (K) of the line control (8) is determined as a function of reports (R) received by it and sent by the line modules (I - VI) when starting up into standby mode, which define their respective functional scope I - VI ) is customizable. [3] Production line according to claim 1 or 2, characterized by that the line control (8) has a settings event function (S) by means of which the software-side configuration (K) of the line control (8) is determined as a function of reports (R) received by it and sent by the line modules (I - VI) by activating the settings event function (S) and defining their respective functional scope. I - VI ) is customizable. [4] Production line according to one of the preceding claims, characterized bythat by adapting the software configuration (K) of the line control (8), only functions supported by all line modules (I - VI) used in the production line (A, B) are available. [5] Production line according to claim 4, characterized by that the data contained in the respective reports (R I - VI ) sent functional scopes of the line modules (I - VI) include information concerning software versions (r, q, x, y, z) used in the line modules (I - VI) and / or hardware components installed therein. [6] Production line according to one of the preceding claims, characterized by that depending on the adapted, software-side configuration (K) of the line control (8), an offer of line articles that can be called up by means of the line control (8) can be changed. [7] Production line according to one of the preceding claims, characterized bythat the line control (8) has a recipe suggestion function for line articles that can be selected by means of the adapted line control (8). [8] Production line according to one of the preceding claims, characterized by that software versions (r, q, x, y, z) of the respective line modules (I - VI) can be updated by means of the line control (8). [9] Production line according to one of the preceding claims, characterized by that the software-side configuration (K) of the line control (8) can be updated depending on data received at the line control (8) from an ERP, MES, MRP, and / or PPS system functionally connected to it. [10] Production line according to one of the preceding claims, characterized by that the line control (8) is configured to, on the basis of the reports (R I - VI ) to the respective line modules (I - VI) Requests (Q I - VI), by means of which settings for various functions can be activated on the respective line modules (I - VI). [11] Method for setting an adaptive line control (8) for a production line (A, B) formed from a plurality of line modules (I - VI), which is in the form of a packaging line (1) or a dough processing line (9), wherein a software-side configuration (K) of the line control (8) is determined as a function of reports (R) received by it and sent by the line modules (I - VI) and defining their respective functional scope. I-VI ) is adjusted, characterized bythat by adapting the software-side configuration (K) of the line control (8), a user interface provided for the line control (8) is adapted in that, when the line modules (I - VI) currently used in the production line (A, B) are started up into a standby mode, at least one operating terminal used along the production line (A, B) supplements or reduces buttons of the line control (8) that can be called up therein with regard to the existing functional scopes of the line modules (I - VI), in order to show a production employee only the buttons in the line control (8) by means of which the line modules (I - VI) used in the production line (A, B) can be controlled. [12] Method according to claim 11, characterized bythat when the line modules (I - VI) are booted into standby mode, the software-side configuration (K) of the line control (8) is adapted depending on reports (RI - VI) received by it and sent by the line modules (I - VI) when booting into standby mode, which define their respective functional scope. [13] Method according to claim 11 or 12, characterized by that by activating a settings event function (S) provided in the line control (8), the software-side configuration (K) of the line control (8) is adapted as a function of reports (RI - VI) received by it and sent by the line modules (I - VI) in response to the activation of the settings event function (S), which define their respective functional scope.

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