Machine and operator-guided method for commissioning machine

Abstract

The invention relates to a machine and to a method for operator-guided commissioning of a machine, in particular on a machine production line for filling and packaging food and / or beverages. According to the invention, the debugging state of the module is read in a programmable logic controller (PLC) of the machine. The debug state of a module is stored in the PLC and displays whether the module has been put into operation. And transmitting a debugging state of the module to a server, and if the debugging state shows that the module is not put into operation, receiving one or more operation instructions from the server. The received operation instruction can be sent to a user. And changing the debugging state of the module based on the operation of the user in the PLC.

Description

Technical Field

[0001] The invention relates to a machine and an operator-guided method for commissioning a machine, in particular a machine on a production line for filling and packaging food and / or beverages. Background Art

[0002] Today, filling and packaging equipment in the liquid food industry is highly optimized and can process up to 120,000 units per hour.A typical filling and packaging equipment usually consists of several different machines and modules connected via conveyor belts.

[0003] These machines are often disassembled when shipped from the manufacturer to the customer, thus losing the characteristics of those tested in the workshop. The size of large machines or machine systems, such as tunnel pasteurizers, makes them impossible to install and test in the workshop. Therefore, these machines are mechanically assembled at the customer's site, where they are wired and put into operation. This highly complex process can lead to numerous errors, necessitating extensive testing of the installation and wiring prior to commissioning.

[0004] The debugger must perform this I / O testing carefully, but often due to time constraints and other issues, these tests are only partially completed.

[0005] For example, the commissioning of complex machines has traditionally been performed based on operator experience. This means that operators determine the necessary steps and checks based on their previous experience with similar machines. This process carries the risk of deviating from specific manufacturer recommendations. Such deviations can result in certain safety-related or performance-optimizing steps being overlooked, potentially impacting machine performance and even causing injury or accidents.

[0006] Another shortcoming of previous approaches was the lack of systematic logging of the commissioning process. This logging is not only crucial for quality assurance and traceability but also crucial for troubleshooting. Without detailed documentation of commissioning activities, it would be difficult to identify or resolve any subsequent issues. In previous commissioning processes, documentation was often left unfinished, leaving it unclear what work and corrections had been performed. Changes in construction site personnel created information gaps that were often unfillable.

[0007] Therefore, existing technologies for complex machine commissioning suffer from at least two significant shortcomings: a heavy reliance on the operator's personal experience, which can lead to deviations from specific manufacturer recommendations, and a lack of systematic, automated logging of the commissioning process. Therefore, a solution is needed to address these gaps and improve safety and efficiency when commissioning complex machines. Summary of the Invention

[0008] The present invention provides a method and a machine for achieving the above-mentioned purpose.

[0009] One embodiment of the present invention relates to an operator-guided method for commissioning a machine, particularly a machine on a production line for filling and packaging food and / or beverages. In this embodiment, the commissioning status of a module is read from a programmable logic controller (PLC) of the machine. The module's commissioning status is stored in the PLC and indicates whether the module is operational. The module's commissioning status is transmitted to a server. If the commissioning status indicates that the module is not operational, one or more operational instructions are received from the server. The received operational instructions may be sent to a user. Based on the user's operation, the module's commissioning status is modified in the PLC.

[0010] Another embodiment of the present invention relates to a machine with operator-guided commissioning. The machine includes at least one programmable controller (PLC), an edge device, and an input-output unit. The PLC stores the commissioning status of at least one module of the machine, indicating whether the module is operational. The edge device transmits the commissioning status to a server and receives operating instructions from the server. The input-output unit transmits operating instructions to a user and receives user input and operating instructions from the server. BRIEF DESCRIPTION OF THE DRAWINGS

[0011] Exemplary aspects of the present invention are illustrated in the accompanying drawings. In the drawings:

[0012] Figure 1 A schematic diagram is shown, which provides an overview of the basic elements and basic structure of the present invention;

[0013] Figure 2 A schematic diagram is shown illustrating an exemplary implementation of a debug state in a programmable controller (PLC);

[0014] Figure 3 An exemplary flow chart of an operator-guided method of commissioning a machine is shown;

[0015] Figure 4 An exemplary equipment configuration for PET containers and bonded strapping is shown;

[0016] Figure 5 An exemplary equipment configuration for a PET container and shrink wrap machine is shown;

[0017] Figure 6 An exemplary apparatus configuration for use with cans or bottles is shown; and

[0018] Figure 7 An exemplary equipment configuration for a can is shown. DETAILED DESCRIPTION

[0019] Figure 1 A schematic diagram is shown, which provides an overview of the essential elements and basic structure of the present invention. For example, a machine line 100 for filling beverages includes one or more machines 101, 102, and 103. Machines 101-103 may be functionally connected, for example, via a conveyor belt that ensures the flow of material. However, the present invention is not limited to a machine line 100 or a plurality of connected machines 101-103. The present invention can also be applied to a single machine.

[0020] Machines 101-103 can be controlled using a programmable logic controller (PLC). A PLC is an electronic device specifically developed to control machines, modules, and equipment in industrial applications. It serves as the interface between the sensors and actuators of a machine or equipment and the actual control program that defines processes and functions. PLCs are well known. The basic functions of a PLC are described below. Essentially, a PLC detects input signals from various sensors (such as temperature sensors, proximity sensors, light barriers, etc.), processes this information according to preprogrammed algorithms or control logic, and then sends corresponding output signals to actuators (such as motors, valves, or relays) to perform certain actions.

[0021] PLC programming is typically performed using specialized software tools and specific programming languages, often based on the IEC 61131-3 standard. This standard defines several programming languages ​​for PLCs, such as function block diagrams. However, the present invention is not limited to this standard and can also be implemented using other standards.

[0022] According to exemplary aspects of the present invention, a PLC may define "inputs," "outputs," and "modules." Examples of inputs include, in particular, sensors, switches, and / or buttons. These can measure physical variables such as temperature, pressure, position, or light intensity. Switches and buttons can be manually manipulated to trigger a state or action in the PLC, such as a start-stop switch for a machine.

[0023] Examples of outputs include actuators, alarm systems, or communication signals. These include motors, valves, heating elements, or lights. For example, a PLC's outputs might open or close a valve in a pipeline, activate an alarm light or buzzer when a certain state is reached, or send a signal to another system or computer to transmit information or trigger actions elsewhere in the networked system.

[0024] In addition, PLCs can also include more complex function blocks, such as the logic module of a PID controller, which is used in many industrial applications to control a process through proportional, integral, and derivative control. These examples give an overview of the different types of blocks (such as input, output, and other function blocks) that can be used in PLC control.

[0025] In addition, if Figure 1 As shown, the edge device 120 can be implemented as a component of the machine 101-103 or the machine production line 100. The edge device 120 can also be coupled to the machine 101-103 as an independent device, or can be a component of the machine 101-103. Data can be exchanged between the machine production line 100 and the server 130 through the edge device 120, for example, Figure 2 Discuss this in more detail.

[0026] In addition, according to some embodiments, an input-output unit 140 may be provided to output machine data, information, or operating instructions to a user 150 (e.g., visually), or to input control commands to the user 150. The input-output unit 140 may be connected to the machine production line 100, each machine 101-103, the edge device 120, and / or a server. The connection may be a direct wired or wireless connection, or an indirect connection via a network (e.g., the Internet or an intranet).

[0027] The input-output unit 140 may be a traditional HMI (human-machine interface) or a mobile device such as a smart phone, a tablet computer, or a computer.

[0028] refer to Figure 2 Further details of the PLC 110 according to an embodiment of the present invention will be described. According to some embodiments of the present invention, an additional module 215 may be implemented in the PLC 110, or additional information may be implemented in each module of the PLC. This additional information, hereinafter referred to as a "debugging status" or "IBN flag" 215, indicates whether the corresponding module of the PLC is operational. The IBN flag 215 may, for example, be a defined bit whose state is "0" or "1," where, for example, "0" indicates that the module is not operational and "1" indicates that the module is operational. The precise determination and implementation of the value of the IBN flag 215 are not limited to this example.

[0029] According to an embodiment of the present invention, when the machine is powered on or started up, each module (function, input, output) implemented in the PLC 110 is "checked" to ensure that the corresponding module is also functioning properly. If this check is not performed before the first commissioning of the machine 101-103, it cannot be guaranteed that the machine 101-103 is functioning properly.

[0030] According to an embodiment of the present invention, as a standard, before the machines 101 - 103 are shipped, the IBN flag 215 of each module in each PLC 110 is set to “0”, ie, “not yet put into operation”, by the manufacturer of the machines 101 - 103 .

[0031] When the input / output / function blocks in PLC 110 are first put into operation, a commissioning process can be initiated. Subsequently, specific routines or functions can be implemented in the PLC program to check or read the status of IBN flags 215. When machines 101-103 are powered on, the edge device can connect to server 130 and transmit the PLC module's IBN flag 215 information to server 130.

[0032] The server 130 can use the IBN flag 215 to identify that the module has not been put into operation, and then create corresponding tasks (i.e., operations or work instructions) for each IBN flag 215 in different modules. Alternatively, the edge device 120 can also only send the IBN flag 215 indicating that the module has not been put into operation or the information contained therein to the server 130.

[0033] The operation instruction received from the server 130 may be received via the edge device 120 and displayed to the user via the input-output unit 140 , for example.

[0034] An example of an operating instruction may be, for example, asking the user 150 to go to a certain dirt collector and clean it, or to go to a defined temperature sensor to take it out and hold it in hand in order to successfully determine the temperature change in the PLC 110 .

[0035] According to some embodiments, the functionality of the machine may also be verified with the help of a digital twin (on the machine 101 - 103 or the server 130 ).

[0036] As a result, each input and output of PLC 110, that is, each module, can be put into operation one after another. User 150 can also report this commissioning to the system via input / output unit 140. User 150 can then terminate this operation command, for example, by inputting and setting IBN flag 215 to "1," i.e., "put into operation." Server 130 can register this commissioning because IBN flag 215 is now "1," no longer "0."

[0037] Optionally, the server 130 may also store corresponding parameter values, which are determined by user operations when parameter settings are required, so that the debugging and the determined values ​​can be documented at the same time.

[0038] The present invention thus improves quality assurance and documentation, since information about commissioning can be transmitted to the server 130. For example, when commissioning each PLC 110, data about the execution, the execution time, and the profile of the user 150 who executed it can be transmitted to the server 130.

[0039] Figure 3An exemplary flowchart of an operator-guided method for commissioning machines 101-103 is shown. In step S302, the method begins when a commissioning state (IBN state) is determined. This step may include immediately initiating a commissioning procedure upon powering on the machine. The commissioning procedure can retrieve the IBN flags 215 of PLC modules. For example, during initialization, the PLC 110 can automatically transmit the IBN flags 215 of each PLC module to the edge device 120. Alternatively, when the machine is powered on, the edge device 120 can automatically request or read the IBN flags from the corresponding PLC.

[0040] In step S304, the value of IBN flag 215 is transmitted to server 130. For example, the value of IBN flag 215 or the debugging status can be transmitted from edge device 120 to the server. Subsequently, in step S306, it is determined whether the PLC module is in operation using IBN flag 215.

[0041] It should be noted that steps S304 and S306 can also be combined, and PLC 110 can independently determine whether the module is operational based on the read IBN flag 215. According to some embodiments, edge device 120 can also send only the IBN flag 215 of the PLC module indicating that the module is not operational to server 130.

[0042] If the module check in S304 indicates that the module is not yet operational, one or more operating instructions may be received in step S308. For example, the operating instructions may be received from server 130 via edge device 120. The operating instructions may be sent to a user or debugger in step S310. For example, the operating instructions may be sent to user 150 via input / output unit 140.

[0043] Subsequently, in step S312, the user or debugger can execute or implement the corresponding instruction. The execution of the instruction can be automatically recognized on the PLC, for example, by a sensor measuring a corresponding sensor event during normal execution of the corresponding instruction. In some embodiments, the operation instruction may also require the user to enter relevant corresponding parameters. These parameters can be stored by PLC 110 and / or edge device 120, and can also be optionally transmitted to server 130.

[0044] When the user executes the operation instruction, the debugging state or IBN flag 215 of the corresponding PLC module in PLC 110 is set from "0" to "1", and the task (i.e., the operation instruction) is marked as "executed" and / or completed on server 130. The change of IBN flag 215 in step S314 can be performed automatically, specifically by PLC 110 registering and recording the user's operation (e.g., via a sensor event), or by user 150 manually transmitting the operation to the PLC via input-output unit 140.

[0045] In optional step S316 , the user 150 may log the execution of the operation instruction and transmit the log to the server 130 as described above, after which the method ends.

[0046] According to the present invention, debugging can provide long-term advantages. Even if the debugger does not understand the PLC's functions or inputs / outputs, they can still fully debug the machines 101-103. The debugging process can be automatically documented, ensuring that the machine status is clearly recorded throughout all subsequent processes.

[0047] Furthermore, the present invention allows multiple commissioning operators to work on machines 101-103 concurrently, without duplication or omissions. This also allows for clear and reliable documentation of work status when personnel change at the construction site, without information loss. The commissioning status is transparent to everyone (on the construction site and in the workshop), resulting in more efficient planning and reduced error rates.

[0048] The commissioning operator does not need to know all the technical details of the machines 101-103 to put the equipment into operation. The operating instructions can guide the commissioning operator to perform various tasks safely. The operating instructions can be translated into other languages ​​to achieve further internationalization.

[0049] A further advantage of the invention is that it can be re-commissioned later (during the life cycle of the machine 101 - 103 ) to detect changes (“Life Cycle Service” (LCS) machine optimization).

[0050] The present invention allows for clear documentation of debugging status and results (for future troubleshooting in the event of a complaint). This allows for lowering the qualification level for some debugging steps, and makes manufacturer technical support more efficient because the manufacturer has access to the status data in server 130, as well as completed and pending tasks. Furthermore, remote debugging solutions can be significantly improved.

[0051] Overall, with the aid of the invention, regulation can be controlled, quality assured and documentation created.

[0052] In the following Figures 4 to 7 Various exemplary apparatus configurations are described in detail for various bottle filling apparatuses in which the present invention, or at least parts and aspects of the present invention, may be implemented. Figures 4 to 7 The description is intended only to provide a general overview of the machines for which status data can be collected and on the basis of which LLM can process user requests.

[0053] Figure 4 An exemplary apparatus configuration 1000 for PET bottles or PET containers and adhesively bonded bundles is shown. Figure 4 As shown, the equipment configuration 1000 includes different modules that form a production line at the end of which the filled PET containers are delivered in bundles on pallets. Some of the modules and machines may be optional, and the present invention is not limited to a specific form and arrangement of the equipment configuration.

[0054] Equipment configuration 1000 includes an oven 1002 for preforms, a preform sorter 1004 with a feeder, and a blow molding machine 1008. Modules 1002, 1004, and 1008 typically form a stretch blow molding machine, in which PET containers are formed and shaped from the starting material. The finished PET containers are then transferred to a filler 1010, where they are filled into bottles. The filler may optionally include a rinser. During storage or transportation, various particles, such as dust and remnants of cardboard or wooden pallets, may accumulate in the preforms. These particles can be removed using a rinser. A sealer may be located at the end of the filler to seal the PET containers after filling.

[0055] Optionally, the plant configuration 1000 may include a carousel 1014 for hot filling of PET containers after the filler 1010. The filled PET containers are conveyed via one or more conveyor belts 1016 (which may also include a buffer 1018 for intermediate loading of filled containers) to a separator 1020 and further to a drying device 1024, in which the PET containers are dried.

[0056] After drying, the PET containers are conveyed to a labeler 1026. Labeler 1026 can be designed for various labeling techniques, such as hot glue, cold glue, self-adhesive labels, or sleeve labels. After printing or labeling, the PET containers are conveyed to a handle applicator 1040 via a second drying unit 1028, a line dispenser 1030, a conveyor belt 1032, an adhesive bundle production unit 1034, and a curing path 1036. In the adhesive bundle production unit 1034, the PET containers are grouped together in specific group sizes and packaged into bundles, such as "six-packs." In the handle applicator, handles are attached to the containers, making the bundles comfortable to carry. The finished bundles are then arranged into layers by a robot 1042 and packaged on pallets by a palletizer 1044.

[0057] In the system configuration 1000, so-called format carts or format racks can be arranged at the various modules and machines to provide quickly exchangeable format sets for short changeover times and automatic tool switching. Examples of format carts are the format cart 1006 for the blow molding machine 1008, the format cart 1012 for the filling machine 1010, the format cart 1022 for the labeling machine 1026, the format cart 1038 for the adhesive bonded bundle production device 1034, and the format cart 1046 for the palletizer 1044.

[0058] Figure 5 Another exemplary equipment configuration 1100 for a PET container and shrink wrap machine is shown. Figure 5 The device 1100 includes a Figure 4 The equipment configuration of the 1000 modules and machines has many modules and machines, however there are some differences. Figure 5 Omitted already combined Figure 4 A description of the module.

[0059] A significant difference between the two exemplary machine configurations 1000 and 1100 is that a labeling machine 1126 with a labeling module 1127 can be installed after the blow molding machine 1008 and before the filling machine 1010. To this end, the machine configuration 1100 can include up to six transport tracks 1150 on which PET containers can enter. After the PET containers have respectively entered one of the six tracks 1150, they are conveyed to a film wrapping module 1152 and then to a shrink tunnel 1154.

[0060] Figure 6 An exemplary device configuration 1200 for cans or bottles is shown. Figure 6 The exemplary device configuration 1200 is again related to Figure 4 and Figure 5The device configurations 1000 and 1100 have some similarities, so the description of the device configurations is limited to the differences in the device configurations.

[0061] like Figure 6 As shown, an exemplary apparatus configuration may include two separate feed sections. Figure 6 The first infeed on the left shows a branch for cans, or alternatively a sub-branch for new, reusable bottles. Here, containers (i.e., cans or new bottles) are introduced into the machine by a depalletizer 1302, where they are guided to a filling machine 1010 via a conveyor belt. Figure 6 The second feed section on the right shows the sub-branch for reusable bottles, which are introduced into the device from a reusable sorting device (not shown).

[0062] In the case where already used reusable bottles are introduced into the apparatus 1200 via the sub-branch for reusable bottles, the reusable bottles first pass through a cleaning or washing machine 1304. Another possible difference in the exemplary apparatus configuration 1200 is a converting packaging machine 1306 following the labeling machine 1026. The converting packaging machine 1306 can sort the bottles or cans into cardboard clip application devices or boxes, or both.

[0063] Figure 7 An exemplary system configuration 1300 for cans is shown, wherein elements already described in other system configurations are not described again. The cans in system configuration 1300 are introduced from a can magazine 1402 containing cans into a depalletizer 1302. After the cans have passed through the filling machine and been filled, they are sealed using a sealing magazine 1404 and transported further along system 1400 via a conveyor belt, as described above.

[0064] If not required, the optional pasteurizer 1408 can be bypassed via bypass 1412. In the pasteurizer 1408, the freshly filled product can be pasteurized for storage.

[0065] Compared to equipment configurations 1000, 1100, and 1200, exemplary equipment configuration 1300 shows different tanks for corresponding consumables, such as tank 1410 for flushing liquid and / or filling product and tank 1406 for lubricant. These tanks can also be included in the exemplary equipment configurations described above. For example, chemical products transferred from a mixer to a machine can be stored in tanks 1406 and 1410.

Claims

1. An operator-guided method of commissioning a machine on a production line for filling and packaging food and / or beverages, wherein the method comprises: reading a debugging status of at least one module in a programmable logic controller (PLC) of the machine, wherein the debugging status of the module is stored in the PLC and indicates whether the module is put into operation; transmitting the read debugging status of the at least one module to a server; If the debugging status of the at least one module indicates that the module has not yet been put into operation, receiving an operation instruction from the server; Sending the received operation instruction to the user; as well as The debugging state of the at least one module is changed in the PLC based on the user's operation instruction.

2. The method according to claim 1, wherein the modules are control routines of input, output and / or function modules in the PLC.

3. The method according to claim 1 or 2, wherein the PLC automatically recognizes the operation instruction of the user with the help of a sensor, and the PLC changes the debugging state based on sensor data. The method according to claim 1 , wherein the PLC changes the debugging state based on manual input of the user.

5. The method according to any one of claims 1 to 4, further comprising: Data regarding the execution of the user's operation instruction is transmitted to the server, wherein the data includes the following information: (i) the operation instruction has been executed, (ii) when the operation instruction was executed, who executed the operation instruction, and / or which parameter values ​​were determined and / or set by the operation instruction.

6. A method according to any one of claims 1 to 5, wherein the operating instructions for the debugging of the module include one or more tests to be performed to determine whether relevant functional characteristics are met and / or whether the correct liquid level sensor in the machine measures a certain liquid level.

7. A machine with operator-guided commissioning for use in a production line for filling and packaging food and / or beverages, wherein the machine comprises: at least one programmable controller (PLC), wherein the PLC is configured to store a commissioning status of at least one module of the machine, wherein the commissioning status of the module indicates whether the module is operational; an edge device configured to send the at least one debugging status to a server and receive an operation instruction from the server; as well as an input-output unit configured to send the operation instruction to the user and receive user input, If the debugging status of the at least one module shows that the module has not yet been put into operation, at least one operation instruction is received from the server via the edge device and displayed via the input-output unit, and the debugging status of the at least one module is changed in the PLC based on the user's operation instruction.

8. The machine according to claim 7, wherein the input-output unit is an HMI, and / or a mobile device connectable to the machine.

9. The machine according to claim 7 or 8, wherein the PLC automatically recognizes the user's operation instruction execution with the help of a sensor, and the PLC changes the debugging state based on the sensor data.

10. A machine according to any one of claims 7 to 9, wherein the PLC changes the commissioning state based on manual input from the user.

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