Adaptive method for orientation of a component

Abstract

An adaptive method for orienting a component in real time, such as a packaging component, in which commands for adjustment are applied to at least one actuator in order to orientate at least one component, the orientated component then undergoes a transformation, and after the transformation, its orientation is measured in order to obtain a measured characteristic of its orientation, the command is gradually adjusted based on the orientation characteristic of the component that has been measured.

Description

[0001] Corresponding application

[0002] This PCT application claims priority to an earlier European patent application No. EP22201943.2, filed on October 17, 2022, in the name of AISAPACK HOLDING SA, the content of which is hereby incorporated by reference in its entirety into this PCT application. Technical field

[0003] The present invention relates to the field of methods for producing packages, and more particularly to flexible packages produced by assembling oriented components. The present invention can be used, for example, to produce packaging tubes, which are particularly but not exclusively intended for packaging liquid or viscous products, semi-liquid products or products in powder form.

[0004] Naturally, the present invention is not only applicable to the production of packaging tubes, but can also be applicable to other fields of production of articles resulting from the assembly of oriented components. Background art

[0005] Publication WO2016055924 (incorporated by reference in its entirety into the present application) proposes a method for orienting a cap relative to a printed tubular body, in which angular correction is determined by considering signals modeled during a learning phase. The method described in WO2016055924 results in a significant reduction in the setup time required, and due to the real-time measurement of the difference between the desired orientation and the measured orientation, it is possible to remove any components that are not correctly oriented from the production batch. This method has many advantages, but when a quality decline is observed, operator intervention is required to adjust the machine commands. Such a quality decline may be related to changes in the environment in which the production machine is located, changes in the components used on the machine (geometry, material), or deterioration associated with the machine (heating, wear).

[0006] Another problem not solved by WO2016055924 relates to multi-track assembly methods for assembling oriented components, in which several assembly tracks are processed sequentially and / or simultaneously, and each track has a different behavior that affects the final orientation between the components. This is particularly the case for a rotating platform including several tracks, such as an indexing turntable including several spindles, each spindle corresponding to a track; see, for example, publications WO2007141711, WO2010054804, and WO2015001453, all of which are incorporated by reference in their entirety into the present application. With this type of equipment, there is a deviation (mean value and standard deviation) between the desired orientation and the measured orientation, which is different for each track. Optimizing the settings of the orientation devices for all tracks as a whole provides the best overall compromise, but this method may be insufficient in cases where the orientation must be very precise.

[0007] The present invention aims to overcome the above disadvantages by an adaptive production method that adjusts the orientation commands and / or parameters of a machine in real time based on the measured characteristics of the oriented articles. In particular, the method allows for individually self-adjusting the orientation of each track to ensure optimal orientation accuracy, regardless of changes in the production environment; regardless of variations between components; regardless of differences in behavior between tracks; regardless of differences in behavior between orientation actuators; and regardless of changes caused by wear and / or heating of the machine. Summary of the Invention

[0008] One object of the present invention is to improve a method and an apparatus for producing packages by assembling oriented components, which are in particular but not exclusively packaging tubes intended for packaging liquid or viscous products, semi-liquid products or solid products (such as in powder form).

[0009] Another object is to propose an adaptive orientation method and station / apparatus that adjusts its commands in real time to obtain assembled components with very precise and uniform orientation, regardless of changes in the production environment, and / or regardless of changes in the nature of the assembled components, and / or regardless of changes related to the production equipment.

[0010] Another object is to propose an orientation method and station that makes it possible to reduce the differences between articles in the same production batch.

[0011] Another object is to propose an orientation method and station that can be implemented simply and effectively.

[0012] Another object is to propose an orientation method and station that can be implemented simply and makes it possible to improve the accuracy of transformation operations; the transformation operations can be, for example, transfer or placement operations; or assembly, welding or bonding operations of components; or molding or overmolding operations; or capping operations involving snap-fitting or screwing components together; or filling operations; or sealing operations, or packaging operations, such as placing an elliptical tube into a box.

[0013] Another object of the present invention is to improve the orientation accuracy used in a method called multi-track, such as a rotary turntable or a parallel linear system. The present invention makes it possible to improve the effective orientation accuracy of a multi-track apparatus using a minimum number of actuators and measurement devices.

[0014] Another object is to propose an orientation method and a modular system that can be implemented on existing machines.

[0015] Other objects and solutions resulting from the present invention will be described below and in the embodiments of the present invention.

[0016] The present invention relates to a method for orienting elements with high productivity, in particular to a single-track or multi-track orientation method implemented on a rotating device.

[0017] The present invention particularly relates to a method for orienting a component in real time using an adaptive command based on the measurement of one or more characteristics of the orientation during production without shutting down the machine. The measured characteristics of the orientation are mainly the deviation between the expected value and the measured value of the orientation, but other characteristics can be determined, such as the average value of the orientation of each track; or in the case of a multi-track configuration, the standard deviation of the orientation of each track. The measurement of these characteristics enables the detection and prediction of any wear or damage of a multi-track rotating device, thereby enabling preventive maintenance. According to the present invention, the characteristics of the orienting component are compared in real time with the characteristics of a reference.

[0018] The present invention particularly relates to a method for orienting a component on a tubular body for packaging; the component is, for example, the head of a tube or a cap, or the neck of a bottle, or the base of a bottle. According to the present invention, the multi-track orientation method can be carried out with high productivity and includes the adjustment of orientation commands that are adaptive and optimized for each track of the machine.

[0019] According to an embodiment of the present invention, the method manages a plurality of actuators, where the actuators are orientation devices or stations that receive orientation commands and place the components in an oriented position. Thus, according to the present invention, the method can manage a plurality of actuators that respectively supply a plurality of tracks. This is particularly the case for a turntable including n by k parallel spindles and k actuators. For example, for a turntable including six by two parallel spindles and two actuators, the total number of tracks is twelve, and each actuator is respectively assigned six tracks. According to another example shown in the publication WO2007141711, the turntable includes eight by six spindles, that is, a total of forty-eight tracks.

[0020] The present invention aims to orient components with high precision and small differences in an assembly process carried out with high productivity.

[0021] In an embodiment, the present invention relates to an adaptive method for orienting a component in real time, such as a packaging component, where an adjusted command is applied to at least one actuator to orient at least one of the components, where the oriented component then undergoes a transformation, and its orientation is measured after the transformation to obtain the measured characteristics of its orientation after the transformation, and where the command is gradually adjusted based on the measured characteristics of the orientation of the component that have been measured after the transformation.

[0022] In an embodiment, the adjusted command is obtained through an adaptive theoretical model that self-adjusts in order to find its optimal parameters.

[0023] In an embodiment, the optimal parameters of the model are obtained by minimizing the deviation between the measured characteristics and the theoretical characteristics calculated by the model.

[0024] In an embodiment, a plurality of components are oriented, each component being on a corresponding track.

[0025] In an embodiment, the measurement of the orientation is optical. Other equivalent means can be used for this measurement.

[0026] In an embodiment, the transformation operation is, for example, an assembly and / or welding and / or bonding and / or molding and / or overmolding operation; and / or a capping operation involving snap-fitting of components; and / or a screwing and / or packaging operation of components, such as placing an elliptical tube in a box. It can also be a combination of several of them.

[0027] In an embodiment, the module for adaptive correction of orientation includes a plurality of self-adjustable theoretical models of the orientation station.

[0028] In an embodiment, the module for adaptive correction of orientation includes a self-adjustable theoretical model for each track of the orientation station and / or for each actuator of the orientation station.

[0029] In an embodiment, the self-adjustable theoretical model is a mathematical function and / or a polynomial function and / or a fractional function, and / or a non-linear function (logarithmic, exponential), and / or a black-box mathematical function, such as a neural network.

[0030] In an embodiment, the parameters of the model are adjusted by an incremental algorithm, RLS (recursive least squares) and / or by quadratic optimization (quadratic programming) and / or by gradient descent optimization.

[0031] In an embodiment, the command is univariate, for example it includes an angular position, and / or the command is multivariate, for example it includes an angular position and / or a rotational speed and / or a torque.

[0032] In an embodiment, an end piece is overmolded on a tubular body.

[0033] In an embodiment, the tube is capped by mounting a cap on the head of the printing tube.

[0034] In an embodiment, the present invention relates to a device for implementing the method described in the present application, the device at least comprising an actuator, a single-track or multi-track transformation device, a device for measuring orientation, and means for processing the measurement, the device further comprising a single-track or multi-track adaptive correction module, the single-track or multi-track adaptive correction module generating optimal parameters for the model of each track and an optimal command for each track. BRIEF DESCRIPTION OF THE DRAWINGS

[0035] The principle of the present invention is illustrated in FIG. 1. The orientation method uses at least an orientation station and a module for adaptive correction of orientation.

[0036] Figure 2 shows an extension of the method shown in Figure 1 to a multi-track (in Figure 2, three tracks are shown by way of non-limiting example) and multi-actuator method. Detailed Description

[0037] Directional station

[0038] The orientation stations 1, 1' perform at least the orientation operation of the component and the operation of measuring the effective orientation of the orientation component in order to determine its actual orientation. After the orientation step and before the step of measuring the actual orientation, the orientation stations 1, 1' perform one or more operations called transformation operations.

[0039] The orientation of the component is performed using actuators 2, 2' known in the prior art and capable of orienting the component with high productivity. An example of a robust actuator 2, 2' that does not require a long setup time due to the use of algorithms is described in the publication WO 2016 / 055924.

[0040] The characteristics of the actual orientation of the component after any transformation operation performed by the transformation devices 3, 3' are measured by measuring devices 4, 4' for measuring orientation, such as optical cameras or optical sensors, or any other suitable sensors. The measurements generated by the transformation devices 3, 3' are processed in the processing devices 5, 5' in order to ultimately obtain the measured characteristics of the orientation of the component in question.

[0041] The operations called transformation operations may include the step of assembling the component, the step of positioning the component (positioning on a conveyor belt, positioning in a cassette, positioning on a mandrel, etc.).

[0042] According to an embodiment of the present invention, the transformation operation is performed on a multi-track indexing turntable 3, 3' for overmolding the head of a tube on a printed skirt. The tube head has, for example, an oval geometry; or, for example, a circular shape with a hole not located on the axis of symmetry. According to some alternative embodiments, the turntable moves continuously.

[0043] According to an embodiment of the present invention, the transformation operation is performed on a multi-track indexing turntable 3 for snap-fitting a hinged lid onto a printed tubular body. According to some alternative embodiments, the turntables 3, 3' move continuously.

[0044] According to an embodiment of the present invention, the transformation operation is performed on a multi-track indexing turntable 3, 3' for welding the lid of a tube onto a printed skirt. According to some alternative embodiments, the turntables 3, 3' move continuously.

[0045] According to an embodiment of the present invention, the transformation operation is performed on a multi-track indexing turntable for welding a base (e.g., an ellipse) onto a printed tubular body. According to alternative embodiments, the turntable moves continuously.

[0046] The turntable mentioned above is, for example, as shown in the prior art bulletins mentioned in this document.

[0047] Module for adaptive correction for directionality

[0048] In parallel with the orientation station, the modules 6, 6' for adaptive correction of orientation adjust in real time the commands of the actuators 2, 2' for orienting the components.

[0049] According to an embodiment of the invention, the modules 6, 6' for adaptive correction of orientation use at least one self - adjustable theoretical model that simulates the behavior of the orientation station 1.

[0050] According to an embodiment of the invention, the modules 6, 6' for adaptive correction of orientation also use the optimal parameters of the real - time self - adjustable theoretical model to calculate the adjustment commands for the actuators 2, 2'.

[0051] Theoretical model

[0052] According to an embodiment of the invention, the modules 6, 6' for adaptive correction of orientation include one or more self - adjustable theoretical models (digital twins) of the orientation stations 1, 1'.

[0053] According to an embodiment of the invention, the modules 6, 6' for adaptive correction of orientation include self - adjustable theoretical models for each track of the orientation stations 1, 1'.

[0054] According to an embodiment of the invention, the modules 6, 6' for adaptive correction of orientation include self - adjustable theoretical models for each actuator of the orientation stations 1, 1'.

[0055] According to an embodiment of the invention, the modules 6, 6' for adaptive correction of orientation include self - adjustable theoretical models for each track and each actuator of the orientation stations 1, 1'.

[0056] According to an embodiment of the invention, the self - adjustable theoretical model is a mathematical function.

[0057] According to an embodiment of the invention, the self - adjustable theoretical model is a polynomial function.

[0058] According to an embodiment of the invention, the self - adjustable theoretical model is a fractional function.

[0059] According to an embodiment of the invention, the self - adjustable theoretical model is a non - linear function (logarithmic, exponential).

[0060] According to an embodiment of the invention, the self - adjustable theoretical model is a black - box mathematical function, such as a neural network.

[0061] Method for real-time adjustment of model parameters

[0062] According to an embodiment of the present invention, the parameters of the model are adjusted in real time by minimizing the deviation between the response of the method (applied to the actuators 2, 2') (to the same command) and the response of the model (the command input into the model), see FIGS. 1 and 2.

[0063] According to an embodiment of the present invention, the parameters of the model are adjusted by an incremental algorithm RLS (Recursive Least Squares).

[0064] According to an embodiment of the present invention, the parameters of the model are adjusted by quadratic optimization (quadratic programming).

[0065] According to an embodiment of the present invention, the parameters of the model are adjusted by gradient descent optimization.

[0066] According to the present invention, the self-adjusting parameters of the model enable the adjustment command for the actuator 1 to be calculated in real time.

[0067] Adjustment command for actuator

[0068] According to the present invention, the adaptive correction modules 6, 6' use an optimized theoretical model and consider the desired characteristics of the orientation as shown in FIGS. 1 and 2 to adjust the commands for the actuators 2, 2' in real time (calculate the adjusted commands considering the desired characteristics of the orientation and the optimal parameters of the model).

[0069] According to an embodiment of the present invention, the command is univariate. For example, the command corresponds to an angular position.

[0070] According to an embodiment of the present invention, the command is multivariate. For example, the command includes an angular position, a rotational speed, and a torque. Within the framework of the present invention, other variables are of course possible.

[0071] Example of the method according to the present invention

[0072] Example 1: Overmolding device

[0073] In a method for producing a packaging tube by overmolding an end piece onto a printed tubular body, the tubular body is oriented before being transferred to an overmolding turntable. The method employs two parallel actuators 2, 2' which orient and distribute the tube body onto a turntable 3, 3' comprising six pairs of mandrels. Transformation operations (transfer of the end piece, overmolding) are performed on the turntable 3, 3'. Two measuring devices 4, 4' mounted on the turntable 3, 3' measure the orientation between the end piece and the tubular body after the transformation operation (in this example, overmolding).

[0074] Parameters of the method of Example 1

[0075] - Twelve tracks (six pairs, in other words twelve mandrels)

[0076] - Two actuators 2, 2', each actuator being assigned to six tracks

[0077] - Twelve theoretical models.

[0078] The present invention enables the optimal orientation of components for each of the twelve tracks and individually (each track having its own theoretical model).

[0079] The present invention enables the real-time analysis of the performance of each of the twelve tracks, the performance of each of the two actuators, and the optimization, anticipation, or correction of any deterioration in the operation of the device.

[0080] Example 2: Capping device

[0081] In the method of capping a tube by snap-fitting a cap onto the head of the printing tube, the cap is oriented before being snap-fitted onto the tube, for example to ensure alignment between the printing surface and the opening of the cap. The method employs an actuator 2, 2' that orients and snap-fits the cap onto the tube, the tube being loaded on a mandrel disposed on a turntable 3, 3'. The rotating turntable 3, 3' includes seven mandrels on which operations are performed successively. Effective orientation between the cap and the tube is carried out after the operations.

[0082] Parameters of the method of Example 2

[0083] - Seven tracks (seven individual mandrels)

[0084] - One actuator 2, 2'

[0085] - Seven theoretical models.

[0086] According to a variant of Example 2, the capping method includes two parallel actuators 2, 2' that orient and snap-fits the cap onto a turntable 3, 3' including seven pairs of mandrels.

[0087] Parameters of the variant of the method of Example 2

[0088] - Fourteen tracks (seven pairs of mandrels, in other words fourteen mandrels)

[0089] - Two actuators 2, 2', each actuator being assigned to seven tracks

[0090] - Fourteen theoretical models.

[0091] Advantages of the present invention

[0092] The present invention enables the achievement of optimized precise orientation for each individual track (each track having its own theoretical model) and minimal orientation differences for each track; this is overall far superior to the optimized general setting for all tracks.

[0093] Due to the integrated self - adjustment function, the present invention enables the time required for setup to be reduced.

[0094] The present invention enables the compensation of deterioration related to machines, the environment, and components.

[0095] Due to the continuous control throughout the production process, the commands for automatically and real - time and independently adjusting the orientation stations 1, 1' for each track are such that the effective characteristics of the orientation on each track are optimal with respect to the characteristics of the desired orientation.

[0096] When deterioration of other characteristics such as the standard deviation (the deviation of the orientation measurement) is measured, the present invention enables the rapid diagnosis and location of defective components or mechanisms and the taking of preventive measures before a failure occurs.

[0097] The principle of the present invention is very economically advantageous because, once deterioration is detected and before a failure occurs, it prevents scrap and limits human intervention by means of the real - time self - adjustment of the machine.

[0098] The embodiments described in this application are illustrative examples and should not be considered restrictive. For example, other embodiments may use devices equivalent to those described. The various above - described embodiments may also be combined with each other according to circumstances, or the devices used in one embodiment may be used in another embodiment.

[0099] Exemplary embodiments have been described to provide a comprehensive understanding of the structure, function, manufacture, and use principles of the systems and methods disclosed herein. One or more examples of these embodiments are shown in the drawings. Those skilled in the art will understand that the systems and methods specifically described and shown in the drawings are non - restrictive exemplary embodiments, and the scope of the present invention is not limited solely by the claims. Features shown or described in connection with one exemplary embodiment may be combined with the features of other embodiments. Such modifications and variations are intended to be included within the scope of the present invention. Many problems with conventional methods and systems are pointed out herein, and the methods and systems disclosed herein can solve one or more of these problems. By describing these problems, it is not intended to admit that they are known in the art. Those of ordinary skill in the art will appreciate that although certain methods and systems are described herein using several non - restrictive embodiments, the scope of the present invention is not limited thereto. Moreover, although the present invention has been described in connection with multiple embodiments, it is apparent that many alternatives, modifications, and variations are obvious to those of ordinary skill in the applicable field. Accordingly, all such alternatives, modifications, equivalents, and variations are intended to be included and covered within the spirit and scope of the present invention.

Claims

1. An adaptive method for real-time orienting components, such as packaging components, wherein, an adjustment command is applied to at least one actuator to orient at least one of the components, wherein the oriented component then undergoes a transformation, and its orientation is measured after the transformation to obtain a measurement characteristic of its orientation after the transformation, wherein the command is gradually adjusted based on the measured orientation characteristic of the component after the transformation.

2. The method according to claim 1, wherein, the adjustment command is obtained by an adaptive theoretical model that self-adjusts to find its optimal parameters.

3. The method according to any one of the preceding claims, wherein, the optimal parameters of the model are obtained by minimizing the deviation between the measurement characteristic and the theoretical characteristic calculated by the model.

4. The method according to any one of the preceding claims, wherein, a plurality of components are oriented, each component being on a corresponding track.

5. The method according to any one of the preceding claims, wherein, the measurement of the orientation is optical.

6. The method according to any one of the preceding claims, wherein, the transformation operation is an assembly, or welding or bonding operation; or a molding or overmolding operation; or a capping operation involving snap fitting or screwing; or a packaging operation, such as placing an oval tube in a box.

7. The method according to any one of the preceding claims, wherein, the module (6, 6') for adaptive correction of orientation includes a plurality of self-adjustable theoretical models of the orientation station (1, 1').

8. The method according to any one of the preceding claims, wherein, the module (6, 6') for adaptive correction of orientation includes a self-adjustable theoretical model for each track of the orientation station and / or for each actuator of the orientation station (1, 1').

9. The method according to any one of the preceding claims, wherein, the self-adjustable theoretical model is a mathematical function and / or a polynomial function and / or a fractional function, and / or a non-linear function (logarithmic, exponential), and / or a black-box mathematical function, such as a neural network.

10. The method according to any one of the preceding claims, wherein, the parameters of the model are adjusted by an incremental algorithm, RLS (recursive least squares) and / or by quadratic optimization (quadratic programming) and / or by gradient descent optimization.

11. The method according to any one of the preceding claims, wherein, the command is univariate, such as an angular position, and / or the command is multivariate, such as the multivariate includes an angular position and / or a rotational speed and / or a torque.

12. The method according to any one of the preceding claims, wherein, end pieces are overmolded on a tubular body.

13. The method according to any one of the preceding claims, wherein, a tube is capped by mounting a cap on the head of the printed tube.

14. An apparatus for implementing the method according to any one of the preceding claims, the apparatus comprising at least an actuator (2, 2'), a single-track or multi-track transformation device (3, 3'), a device (4, 4') for measuring orientation, and a device (5, 5') for processing the measurements, the apparatus further comprising a single-track or multi-track adaptive correction module (6, 6'), the single-track or multi-track adaptive correction module generating optimal parameters for the model for each track and optimal commands for each track.

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