Method for controlling production process in production line, and production line, in particular filling line

Abstract

The invention relates to a method for controlling a production process having at least two production processes connected in series for producing and / or processing containers, in particular bottles, in a production line comprising a filling of a liquid product, connected upstream of the filling or connected downstream of the filling. In this way, data records relating to the entire production process are individually assigned to the containers. The data record is enhanced with process and / or container-specific production data when undergoing the production process. Therefore, the production line can be comprehensively optimized under the condition that a single process step and a process result are traced.

Description

Field of the Invention

[0001] The present invention relates to a method for controlling a production process having production processes connected in series for manufacturing and / or processing containers in a production line, and to a corresponding production line, in particular a filling line. Background Art

[0002] It is known that in filling equipment, production data (such as inspection data) is combined with information of the respective processing stations being processed for individual process units. For example, in the case of plastic bottles, wall thickness data is analyzed, and these wall thickness data are assigned to blow molding cavities, fixture numbers, and heating core numbers. Correspondingly, the accumulation of faults is displayed, and these faults can be assigned to specific cavities, fixtures, or heating cores, which simplifies fault finding.

[0003] Furthermore, it is known to track containers in a container handling machine by means of a shift register. Here, the machine processes the information assigned to the containers in coarse and / or high beats.

[0004] It is also known from EP 2 132 129 B1 to query the occupancy of bulk conveyors and / or buffer sections for containers in a filling equipment by means of one or several cameras.

[0005] The disadvantage is that only fault analysis can be carried out for each individual machine, and the optimization of production can often only be carried out insufficiently and / or in many separate steps.

[0006] Therefore, there is a need for improvement in this regard. Summary of the Invention

[0007] The task proposed is solved by the solution of the present application. Preferred embodiments are mainly given in other solutions. It should be understood that the production line can be configured to implement the described method steps, and the corresponding method steps can be implemented by using the described production line functions.

[0008] Therefore, the claimed method is used to control a production process having at least two production processes connected in series for manufacturing and / or processing containers, in particular bottles, in a production line, and the production line includes filling of a liquid product, connected upstream or downstream of the filling. For this purpose, data records regarding the entire production process (i.e., at least from the start to the end of the production process) are individually assigned to the containers, and these data records are enhanced with process- and / or container-specific production data when passing through the production process.

[0009] The claimed production line correspondingly includes a filling machine for filling liquid products into containers, in particular bottles, or is connected upstream or downstream of the filling machine. The production line includes at least two process units connected in series with each other by at least one transport means for manufacturing and / or processing containers, and includes a monitoring system which is adapted to individually assign data records regarding the production processes implemented in the process units to the containers, and to enhance these data records with process- and / or container-specific production data when undergoing the production process, in particular according to at least one of the methods described in the embodiments.

[0010] In this way, cross-machine relationships that affect the efficiency of the respective production line can also be better identified and systematically analyzed, so as to formulate corresponding optimization plans if appropriate on this basis.

[0011] These data records can be individually assigned to the containers within the area of at least one transport section that forcibly guides the containers through a shift register, and these data records are particularly enhanced with the production data of the respective production process thus experienced.

[0012] These data records can be individually assigned to the containers within the area of a transport section that does not forcibly guide the containers through the imaging transport tracking of the containers, in particular a transport section for the disorderly bulk transport of containers or a transport section that does not adopt the First-In-First-Out method, and these data records are particularly enhanced with the production data of the respective production process thus experienced.

[0013] Similarly, under the condition of a constant production output in the immediately adjacent upstream, these data records can be individually assigned to the containers within the area of a transport section that does not forcibly guide the containers through transport time monitoring, in particular the single-track air transport of containers or a transport section that adopts the First-In-First-Out method, and these data records are particularly enhanced with the production data of the respective production process thus experienced.

[0014] The transport sections can each be a component part of a process unit or connect these process units.

[0015] These data records can also be regarded as a virtual data backpack of a single container or an information container accompanied electronically.

[0016] The production process for manufacturing containers, for example, is to heat the preform and blow a plastic bottle. Here, processing is understood to mean all other production processes in the production flow, such as labeling, filling a liquid product into the container, and packaging the filled container, for example, each having a suitably allocated inspection at the entrance and / or exit of an individual production process or a process unit constructed for this purpose.

[0017] The production flow can also be understood as a production cycle, where the start and end of this production flow can in principle be arbitrarily defined, such that such a cycle does not necessarily have to involve raw materials nor the final product.

[0018] These data records are thus used to identify or label individual containers and remain assigned to these containers throughout the monitored production flow or cycle. For this purpose, the corresponding data records can include at least the number of the respective process unit known due to the machine configuration of the production line and the associated time stamp. For example, it is then specified: which processing unit (heating core, clamp, blow mold, filling valve, capping unit or the like) received the container at what time.

[0019] The container-specific data records can include data that is available at the individual shift register positions of the process unit being processed or the transport means used.

[0020] The data records can, for example, include: preform batch information from a specific flip time point to the respective next flip time point when entering the shift register; individualized preform feed temperature; infrared absorption values at the shift register positions of the relevant measurement points; individualized preform temperature after heating at the corresponding shift register positions; characteristic values in the blow curve analysis of the shift register that relates to the container at the exit of the blow wheel and its respective associated blow mold cavity.

[0021] Using the time stamp and the last shift register position enhanced with data as described, for example, the complete history of an individual container in the production flow or cycle can be reconstructed, and if appropriate, only a part of it that needs to be inspected can also be reconstructed. For example, the process data of a container that ruptured in the filling machine, such as heating and blowing parameters, can be traced, and similarly, the individualized relevant preform feed temperature can be traced. These data can also be written at an earlier time point.

[0022] The data records can be read and used through the shift register information of an individual process unit (such as a blow molding machine, etc.) of the process control system to optimize process parameters, for example, to adapt to a specific preform feed temperature.

[0023] The corresponding container identification can be simply maintained or assigned through the shift register, for example, via the corresponding time stamp and / or the time course in the shift register.

[0024] Therefore, the physical marking of the container itself is redundant.

[0025] When transporting without forced guidance to determine or obtain the corresponding transport position in the container flow (e.g., in a star gripper or furnace gripper), container tracking and data assignment are feasible through counting functions, time measurement, and / or image monitoring. In the case of air transportation, one can, for example, use the counting function after each evacuation. Therefore, one cannot monitor the diverter switch that works based on the transport position.

[0026] In the case of forced guidance of the container, for example, in a machine block, information in the database can be assigned to each container or each relevant shift register position, i.e., which processing device, which processing station, or which transport gripper (transport star) has subsequently processed or transported a specific container. Corresponding information, such as online measurement results (e.g., wall thickness, filling height level, etc.), and fault information, such as quality rejection (e.g., bottle breakage, label skew, etc.), can be assigned to individual containers or relevant shift register positions respectively.

[0027] In forced guidance or block applications, a 1:1 assignment relationship between individual containers and transport positions (regarding the product flow) can always be achieved through shift registers. All relevant process units with several (cyclic) processing stations require information about their current (rotating) positions for this purpose. This information can be provided, for example, by the corresponding drive device, such as a stepper motor, or can be derived from the cycle rhythm, for example, through proximity switches at each processing station. Possible participants in a monitoring system based on shift registers are, for example, all process units with several processing stations, such as blow molding machines, cyclic washing machines, parison ovens chains, parison radiation stars, orientation stars, and, if appropriate, transfer stars and / or labeling machines.

[0028] In the case of non-forced guidance of the container, for example, in air transportation applications that work according to the first-in-first-out principle, it may also be possible in principle to use shift register positions. Since there does not necessarily always exist a defined 1:1 assignment relationship (see above), for example, due to quality rejection, the time delay of container transportation can be used instead or in addition to identify the identity of the container and assign the described data records.

[0029] For example, in the production phase where all participating process units produce at linear capacity, the time delay between individual containers remains almost constant. This can be accurate enough to solve errors in filling machines, for example, "burst bottles" due to insufficient container quality, through the correction loop of each blow molding machine. Similarly, it may be possible to assign fault images at capping machines, labeling machines, shrink wrapping machines, bulk transportation tools, or similar equipment to specific causes and / or machine setting parameters.

[0030] Supplemented, it may also be feasible to perform allocation via physical container marking. For example, the marking may be applied specifically at the respective next process unit, either after the production gap or at the respective first container after quality rejection, such as by laser engraving, direct printing, UV pen, etc. If there is no other diversion function in the transport section without forced guidance or shift register allocation, a 1:1 allocation relationship can be (re)established in this way.

[0031] For the transition between forced-guided container transport (such as star fixtures, filling valves, rotary disks, blow molding dies, etc.) and non-forced-guided container transport that does not follow the first-in, first-out principle (such as overflow sections, bulk flow, and buffer storage), it is advantageous that the graphical container tracking is continuous starting from the respective transition from forced-guided container transport or until the respective transition to forced-guided container transport.

[0032] This graphical transport tracking of containers is feasible using at least one camera. Specifically, in a generally known manner, each container within the imaging area (field of view) is electronically marked through image processing, so that each container can be uniquely identified and tracked in the bulk flow. For this purpose, the container and its electronic marking can be transferred between the imaging areas of several cameras in a known manner.

[0033] To achieve a traceable transfer from non-forced-guided container transport to forced-guided container transport, an overlapping area is advantageous. In this overlapping area, the container is already forced-guided, but is still tracked through camera tracking here, so as to transfer the data record of the container from camera tracking to the machine register on this basis. Such an overlapping area preferably has a length (in the transport direction) that is equal to the diameter of the container to be processed up to ten times, for example, a length of 0.05 m to 1 m. Then, the container identification and related process data obtained thereby can be transferred to the relevant machine displacement register, such as for the transport section of a rotary machine that cannot be fully viewed.

[0034] In addition, there is also the possibility of converting the camera tracking into a first-in, first-out area and back, for example, if there is a cross passage above the conveyor, such as a ladder.

[0035] This is performed, for example, at the feed screw or feed serrated star, but is also feasible in principle at a conveyor belt, feed belt, or similar equipment. Precise positioning synchronization can be achieved, for example, via a triggered photoelectric switch, but can also be directly written by the graphical tracking system into the corresponding machine shift register (feed screw or feed serrated star) and further processed there.

[0036] Method steps implemented in a production line during container transportation or container handling are recorded by the respective process units (container handling machines) as process- and / or container-specific production data and stored as a data record accompanying the respective container along the production line. This data record thus grows continuously with each production process, yet always remains assigned to an individual container, for example based on the respective shift register position and / or graphical container tracking.

[0037] The production data can be measured actual values, target values, evaluation results of individual processes, or status data and / or identification data of filling mechanisms, sealing mechanisms, reaction chambers, mold cavities, or the like. The production data can also include inspection results, such as detected container defects, and / or control criteria, such as for subsequently diverting individual containers.

[0038] The described monitoring system is specifically configured to transfer the container and its associated data record from forced-guided transportation (associated data management via a shift register, i.e., machine tracking) to non-forced-guided transportation (without first-in, first-out, i.e., graphical container tracking in a bulk flow), and vice versa.

[0039] Therefore, such data transfer is also advantageous because if the container passes through a transport section that cannot be adequately viewed and / or the appearance of the container changes due to manufacturing or handling, it is difficult or even impossible to perform only graphical container tracking. In these areas, forced guidance, i.e., the specified transport position in the product flow, and data management in the shift register enable unambiguous identification of the container and non-optical assignment of the data record, and also simplify the process of learning graphical container tracking after an external change to the container, i.e., in the case where the image information changes accordingly. Description of the Drawings

[0040] A preferred embodiment of the present invention is shown exemplarily in Figure 1 It shows a schematic top view of a production line. Detailed Description of the Invention

[0041] Accordingly, the production line 100 includes at least one first process unit 1, which is, for example, a filling machine for filling a liquid product into containers 10 - 52, and includes at least one second process unit 2, which is, for example, a packaging machine.

[0042] Upstream of the first process unit 1 and between the first process unit and the second process unit 2, transport means 3a, 3b are arranged for non-forced-guided transportation of the containers 10 - 52 in the form of an unordered bulk flow (without first-in, first-out).

[0043] The first process unit 1 further includes a transport means 1a for transporting the containers 10 - 52 in a forced - guiding manner. Here, taking the container turntable as an example, the container turntable has circumferential stations V1 - V16 (filling valves) each accommodating one container 10 - 52.

[0044] Correspondingly, the transport means 3a, 3b form a first transport section 4a and a third transport section 4c for transporting the containers 10 - 52 in a non - forced - guiding manner respectively, and the transport means 1a forms an intermediate second transport section 4b for transporting the containers 10 - 52 in a forced - guiding manner.

[0045] The production line 100 further includes a monitoring system 5, which is adapted to individually assign associated data records 6 (only some of which are schematically indicated by arrows) to each individual container 10 - 52. These data records relate to the production processes implemented in the process units 1, 2, which here include the unordered removal of empty containers, the filling of the containers (and sealing, not shown), the unordered transfer of the filled containers to the packaging machine, and the packaging of the containers 10 - 52.

[0046] When the individual data records 6 of the containers 10 - 52 go through the production process, during Figure 1 filling (and sealing) and packaging respectively, they are enhanced with process - and / or container - specific production data 6a or 6b.

[0047] For this purpose, the monitoring system 5 includes: a first tracking system 5a assigned to the first transport section 4a for image - based transport tracking of the containers 10 - 52 in the bulk flow through cameras C1 and C2; a (machine) shift register 1b assigned to the second transport section 4b and thus to the first process unit 1; and a second tracking system 5b assigned to the third transport section 4c for image - based transport tracking of the containers 10 - 52 in the bulk flow through camera C3. The cameras C1 - C3 can be arranged, for example, in a telecentric manner on the assigned transport means 3a, 3b.

[0048] Through the tracking systems 5a, 5b and the shift register 1b, during the production process, the data records 6 always remain assigned to the corresponding containers 10 - 52, and are respectively enhanced with the production data 6a or 6b generated there within the areas of the process units 1, 2. Correspondingly, the data records 6 each reflect the individual production history of the containers 10 - 52 at the end of the production process and are preferably stored for subsequent evaluation / product tracking, which is feasible in a generally known manner and thus will not be elaborated here.

[0049] In this example, all containers 10-52 are identified by a first tracking system 5a and correspondingly electronically marked using the number 10-52 and, for example, current position information of the corresponding container 10-52 in at least one camera image, as well as additional information such as type and an individualized 2-D code, which is assigned, for example, during manufacturing (in a blow molding machine not shown).

[0050] If a container 10-52 reaches the first transfer point 7a between the first and second transport sections 4a, 4b, the relevant data record 6 (if already present) is transferred from the first tracking system 5a to the shift register 1b. The data record 6 is here recorded position-synchronously by the shift register 1b of the first process unit 1 using a rotary encoder in the sense of a virtual information container or data backpack. In this case, the data record 6 is enhanced with production data 6a, which relate, for example, to the respective stations V1-V16 (filling valves) used, the sealing heads used, the product filled and / or the filling temperature. Likewise, the production data 6a can indicate fault states or the like. In the example, a broken container 33 is found at V2 (e.g. a broken bottle). This information is included in the data record 6 of the container 33 (i.e. a container with the previously assigned identification number 33). On this basis, the container 33 is diverted before, for example, reaching the second tracking system 5b. The relevant, correspondingly enhanced data record 6 can then be transmitted, for example, to a higher-level control system and stored therein, so that it is no longer transferred to the system at the second transfer point 7b with the second tracking system 5b.

[0051] The remaining containers 10 - 32 and 34 - 52 pass the second transfer point 7 b , wherein their data records 6 enhanced with production data 6 a are transmitted to the second tracking system 5 b , for example together with the receiving coordinates of the system, while maintaining the container identification.

[0052] In the second process unit 2, the data records 6 of the (here remaining) containers 10-32 and 34-52 can be further enhanced with the production data 6b generated there, so that the process flow or process cycle shown here by way of example is completed and stored, for example for use in a higher-level control system (not shown).

Claims

1. A method for controlling a production process having at least two production processes connected in series for manufacturing and / or processing containers (10-52) in a production line (100), the production line comprising the filling of a liquid product, connected upstream of the filling or connected downstream of the filling, wherein a data record (6) relating to the entire production process is assigned to the container and the data record is enhanced with process- and / or container-specific production data (6a, 6b) as it passes through the production process.

2. A method according to claim 1, wherein the data records (6) are individually assigned to the containers (10-52) in the area of ​​at least one transport section (4b) in which the containers are forcibly guided by at least one shift register (1b), and the data records are enhanced in particular with the production data (6a, 6b) of the production process each of which has undergone this process.

3. The method according to claim 2, wherein the container (10-52) is thus guided through a closed structure under forced guidance and / or undergoes a change in its appearance and / or is processed in a circulation station (V1-V16) and / or is transported by a circulation rack.

4. A method according to any of the preceding claims, wherein the container (10-52) is changed during the production process: in terms of its shape, in particular by transforming the parison into a product container for a liquid filling; and / or in terms of its content, in particular by filling with the liquid filling; and / or in terms of its configuration, in particular by labeling and / or sealing.

5. A method according to any of the preceding claims, wherein the data records (6) are individually assigned to the containers (10-52) in the area of ​​transport sections (4a, 4c) without forced guidance by means of graphical transport tracking of the containers, which transport sections do not operate according to the first-in-first-out principle, and in particular the data records are enhanced with the production data (6a, 6b) of the production processes each of which has undergone this process.

6. A method according to at least one of the preceding claims, wherein the data records (6) are individually assigned to containers (10-52) in the area of ​​a transport section without forced guidance by transport time monitoring under the condition of a constant production output in the respective immediate upstream region, the transport section operating according to the first-in-first-out principle, and the data records are in particular enhanced with the production data (6a, 6b) of the production process thus undergone.

7. A method according to at least one of the preceding claims, wherein the data record (6) accompanies the container (10-52) electronically after being enhanced with process and / or container-specific production data (6a, 6b), wherein the data record is in particular transferred between the transport sections (4a-4c) with and without forced guidance and is stored after passing through the process units (1, 2).

8. A method according to at least one of the preceding claims, wherein the process-specific production data (6a, 6b) include at least one actual value of a relevant processing parameter measured in the corresponding production process, and the container-specific production data reflect at least one container characteristic measured before, after or during the corresponding production process.

9. A production line (100), comprising a filling machine for filling liquid products into containers (10-52), connected upstream of the filling machine or connected downstream of the filling machine, having at least two process units (1, 2) connected in series with each other via at least one transport means (3b) for manufacturing and / or processing the containers, and having a monitoring system (5), which is adapted to individually assign data records (6) about the production process implemented in the process units to the containers and to enhance the data records with process and / or container-specific production data (6a, 6b) when undergoing the production process, in particular according to the method according to at least one of the above claims.

10. Production line according to claim 9, wherein the monitoring system (5) comprises at least one shift register (1b) which is assigned to a process unit (1) and / or a transport means in which the container (10-52) is forcibly guided, and wherein, The monitoring system is adapted to individually assign the data record (6) to the container via the shift register and to enhance the data record on this basis with production data (6a, 6b) of the process unit and / or transport vehicle thus passed through.

11. Production line according to claim 9 or 10, wherein the monitoring system (5) comprises at least one tracking system (5a, 5b) for graphically tracking the transport of the containers (10-52), which tracking system is assigned to process units and / or transport vehicles (3a, 3b) in which the containers are not necessarily guided, in particular in the form of unordered bulk transport, and wherein, The monitoring system is adapted to individually assign the data record (6) to the container via the tracking system and, in particular, to enhance the data record on this basis with production data of the process unit and / or transport vehicle thus experienced.

12. A production line according to any one of claims 9 to 11, wherein the monitoring system (5) comprises an overlapping area at the transition from non-forced guidance to forced guidance of container transport, in which the containers (10-52) are already forced guided but are still tracked in an image-based manner, so that on this basis the data records (6) of the containers are transferred from the tracking system (5a, 5b) for image-based transport tracking. 5b) is passed to the shift register (1b).

13. The production line according to claim 12, wherein the overlapping area has a relative length which is at least equal to up to ten times the diameter of the container (10-52) to be processed and / or has an absolute length of 0.05 m to 1 m.

14. Production line according to any one of claims 9 to 13, wherein the monitoring system (5) comprises at least one operating time control system for measuring the operating time of individual containers (10-52), the operating time control system being assigned to process units and / or transport vehicles in which the containers are not necessarily guided, in particular in the form of air transport on respective monorails, and wherein The monitoring system is adapted to assign the data records (6) individually to the containers via the runtime control system under the condition of a constant production output in the respective immediate upstream region and to enhance the data records in particular based thereon with the production data of the process units and / or transport means thus experienced.

15. The production line according to claim 9 , wherein the monitoring system ( 5 ) is adapted so that the data records ( 6 ) electronically accompany the containers ( 10 - 11 ) after being respectively enhanced with process and / or container-specific production data ( 6 a, 6 b ). 52), wherein the data record is in particular transmitted at least between the shift register (1b), the tracking system (5a, 5b) and / or the runtime control system and is further stored with its production data (6a, 6b) after passing through the process unit (1, 2).

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