Method for monitoring a container processing system

Abstract

The invention relates to a method for monitoring a container handling system, comprising a conveying device for conveying containers (1), in particular beverage containers, and comprising at least one handling device (2) arranged at least partially along the conveying device for handling the containers (1). According to the invention, an acoustic signal is detected during operation of the processing system, and the acoustic signal is compared with at least one reference signal in order to determine the machine state and / or the operating state.

Description

Technical Field

[0001] The invention relates to a method for monitoring a container treatment system comprising a conveying device for conveying containers, in particular beverage containers, and at least one treatment device assigned to the conveying device for treating the containers during the conveying process. Background Art

[0002] Such processing systems are known in the prior art and can process containers in various ways. The present invention relates in particular to containers used in the beverage industry. Therefore, it is preferably concerned with beverage containers. These can be, for example, in the form of glass or plastic bottles. However, it is also conceivable to provide beverage containers in the form of beverage cans made of thin-walled sheet metal (e.g., aluminum).

[0003] Furthermore, within the scope of the present invention, so-called preforms or preforms are also understood to mean containers. These preforms typically have a prefabricated container head with an external thread for receiving a closure cap. These preforms are then conveyed to a blow molding machine where they are formed into beverage bottles. The preforms are therefore made of thermoplastic material, particularly thermoplastic plastics such as polyethylene terephthalate (PET). They are then heated and conveyed to a blow molding machine. By applying internal pressure to the preforms, they are pressed into a mold and thus assume the shape of a beverage bottle.

[0004] The preform is thus subjected to a blow-molding process. Furthermore, the invention also relates to other treatments in which the container is subjected to some form of physical and / or optical influence.

[0005] Regardless of the treatment method, it is known that different machine states and / or operating states can exist depending on the type of container handling system. Within the scope of the present invention, operating states are defined as all states of a container handling system that can be specifically set and thus define the undisturbed operation of the container handling system. This includes, for example, the capacity of the container handling system, where a high capacity allows a correspondingly large number of containers to be processed per hour, while a low capacity allows a smaller number of containers to be processed per hour.

[0006] The machine status, on the other hand, refers to machine faults or faults during machine operation. These faults can be of various natures and, for example, indicate material wear on the machine or on the transported containers. Furthermore, it is also conceivable that, for example, individual machine operating processes are not optimally synchronized with one another, leading to deviations from the optimal machine status.

[0007] Known container handling systems in practice include a number of monitoring devices, which are used, in particular, to monitor the operating status. For example, information can be read out to provide the user with information indicating whether individual system components, particularly valves, have switched. However, it may be useful to implement additional measures to independently verify whether the switch has actually occurred. A particularly problematic issue in this regard is that even if a valve is damaged, the user is still informed that the switch has occurred. However, the user cannot determine the extent of the change in operating status caused by the valve switching. Even with previously known monitoring devices, other faults cannot be easily identified, so damage or wear of individual components is often only discovered during regular maintenance. Summary of the Invention

[0008] Against this background, the object of the present invention is to provide a method for monitoring a container handling system which allows reliable conclusions to be drawn about the machine state and / or the operating state.

[0009] According to the invention, for this purpose, an acoustic signal is detected (in particular continuously) during operation of the treatment system and is compared with at least one reference signal in order to determine the machine state and / or operating state.

[0010] An acoustic sensor is preferably provided for detecting the sound signal, in particular a microphone which converts the sound signal in the form of pressure fluctuations into an audio signal with a voltage.

[0011] The acoustic signal can, in particular, be sound intensity and / or sound frequency. Both types of signals can characterize a specific machine state and / or operating condition. For example, due to a fault and / or component failure, the sound intensity may increase and accordingly deviate from the sound intensity that characterizes the operating condition. In this case, the reference signal can be defined by an upper and / or lower limit value. If the limit value is exceeded or exceeded, it can be associated with a specific machine state and / or operating condition in the evaluation unit.

[0012] The same applies to the sound frequency. For example, the sound frequency may change due to a change in the operating state, for example, because a higher container throughput is set in the container handling system. This sound frequency can then also be compared with corresponding limit values, each of which represents a corresponding operating state and / or machine state.

[0013] In particular, it is provided that the acoustic signal is analyzed and evaluated in an evaluation unit. For this purpose, the acoustic sensor is connected to the evaluation unit. A comparison with a reference signal is then performed in the evaluation unit, and an output signal can then be sent to a user. This output signal can indicate a specific machine state and / or operating state. The output signal can be optical and / or acoustic.

[0014] Alternatively or additionally, the reference signal can also be a characteristic signal pattern that characterizes the machine state and / or operating status. The course of the sound intensity and / or sound frequency during the measurement period is then recorded and evaluated by comparison with the characteristic signal pattern. For example, it is conceivable that the sound intensity increases at short intervals during the measurement period and then decreases again due to a fault. This recurring signal pattern can then be stored in the evaluation unit, making it possible to determine the machine state and / or operating status based on it.

[0015] For monitoring the container handling system, a monitoring device is preferably provided, wherein the evaluation unit is also a component of the monitoring device. This results in different possibilities for determining and storing the reference signal.

[0016] For example, reference signals, particularly those characterizing machine states and / or operating conditions, can be stored in advance in the evaluation unit. In this case, the detected acoustic signal is then compared with the stored reference signals. To store the reference signals, the evaluation unit preferably includes a memory unit for storing data.

[0017] Furthermore, the reference signal can be continuously supplemented during operation. For example, it is conceivable that the evaluation unit detects an acoustic signal that deviates from a stored reference signal during operation. Therefore, this acoustic signal cannot be associated with any machine state and / or operating state. A corresponding notification can then be provided to the user by issuing an output signal. For example, during system testing, a correlation can be established between the measured acoustic signal and a specific machine state and / or operating state. The acoustic signal thus detected can then be stored as a reference signal in a memory unit of the evaluation unit.

[0018] Furthermore, algorithms based on artificial intelligence and / or neural networks can also be stored in the evaluation unit. In this case, the evaluation unit can store independently measured acoustic signals as reference signals for the machine state and / or operating state. In this regard, the at least one acoustic sensor can be used both to determine the machine state and / or operating state and to determine the reference signal.

[0019] Alternatively, provision can be made to detect an acoustic signal in a first operating position and a reference signal in a second operating position. Thus, at least two acoustic sensors are provided, which detect acoustic signals independently of one another in different operating positions. The two measured acoustic signals can then be compared with one another, and characteristic machine and / or operating states can be determined based on deviations in the signals.

[0020] A development of the invention provides that the measured acoustic signal is generated by the fluid flow and / or by structure-borne sound of system components. Monitoring is particularly carried out in container handling systems in which fluid handling containers are used. Therefore, the fluid provided for handling is precisely suitable for monitoring. In the case of a blow-molding system, for example, one or more blowing units constitute the handling system. In this case, typically one blowing unit is each assigned to a container receiving device of the conveying system and typically moves together with the container receiving device. The containers are then formed during the conveying process, with the blowing units blowing compressed air into the containers or preforms arranged in the container receiving devices, respectively. In the case of a blow-molding system, the container receiving device is typically designed as a blow mold, the internal contour of which corresponds to the internal contour of the beverage container to be produced. By introducing compressed air into the preform, the preform is pressed against the internal contour and simultaneously plastically deformed.

[0021] The acoustic signal can then be used to identify leaks within the corresponding blow molding station or venting of the blow mold. Furthermore, the position of individual valves can be identified, allowing valve misalignment to be avoided in good time. This is particularly advantageous in the case of overlapping valves. It also reduces the dead time between valve switching.

[0022] However, the present invention is not limited in principle to processing devices in the form of blowing devices. Rather, the containers can be processed in which the processing type is selected from the group consisting of blow molding, stretch blow molding, container sorting, container filling and / or container labeling.

[0023] Stretch blow molding differs from blow molding in that a stretch rod is additionally inserted into the preform, thereby stretching the preform along the container axis.

[0024] Container sorting is particularly important when it comes to containers in the form of preforms. In this case, the preforms are often aligned and sorted using roller conveyors. Microphone integration allows for the detection of both preform blockages and gaps within the preform chain. Damaged preforms can also be detected.

[0025] Beverage containers are typically filled with beverages in a filling system, typically a processing system. The beverage can be provided in both static and carbonated form. Acoustic sensors can, for example, detect overflow losses. Valve switching can also be monitored.

[0026] If the processing device is designed as a labeling system, acoustic sensors can be used to detect any discrepancies in the label supply or whether labels are adequately retained on the labeling wheel. Labels are typically retained on the labeling wheel by negative pressure, which is in turn generated by a vacuum system. Therefore, the functional status of the vacuum system and / or the labeling wheel can be monitored using the at least one acoustic sensor.

[0027] Furthermore, the acoustic sensor can be arranged on the conveyor device so as to be movable, in particular rotatable. The conveyor device is usually configured as a conveyor star, so that the material is processed along a circular conveying path. However, the acoustic sensor can also be arranged stationary.

[0028] Furthermore, the subject matter of the present invention is a container handling system according to claims 10 to 15 for carrying out the method according to the invention according to claims 1 to 9, which container handling system comprises a conveying device for conveying containers, in particular beverage containers, and comprises at least one handling device for handling containers, which is arranged at least partially along the conveying device.

[0029] Based on this design, the present invention provides a monitoring device for detecting and analyzing acoustic signals. The monitoring device includes at least one acoustic sensor and an evaluation unit connected to the at least one acoustic sensor. The evaluation unit has been described in detail above. For example, the evaluation unit may include a storage unit in which a large number of reference signals are stored.

[0030] The at least one acoustic sensor is assigned to the processing device and / or the conveying device.

[0031] Preferably, the blow molding station has a blow channel for introducing blow molding air into the preform, wherein at least one acoustic sensor is arranged in the blow channel. As an alternative, the at least one acoustic sensor and the blow channel can be connected indirectly or directly by sound conduction.

[0032] A further development of the invention provides that the blow moulding station has a stretch rod in which the at least one acoustic sensor is arranged.

[0033] In particular, the present invention provides for the processing device to be configured as a blowing device having one or more blowing units for blow molding, in particular stretch blow molding, preforms into beverage containers. Based on this processing system, the blow molding station has a blow channel for introducing blowing air into the containers. According to this design, the conveyor device has a plurality of container receiving devices, each of which is assigned a blowing unit. In this case, the blowing units can be arranged fixed relative to the container receiving devices so that they move together with the movement of the container receiving devices. Preferably, the container receiving devices are configured as blow molds in this case.

[0034] The container receiving device and the blowing unit are preferably arranged on a support that can be driven to rotate, so that in the container rotation process, the container is conveyed and processed. Of course, if other processing methods should be specified, this also applies equally.

[0035] In addition, the blow molding station can also have a stretching rod. So, at least one acoustic sensor can also be arranged in this stretching rod. BRIEF DESCRIPTION OF THE DRAWINGS

[0036] Figure 1 A container handling system for blow molding according to the present invention is shown;

[0037] Figure 2 yes Figure 1 Partial section in the area of ​​the blowing channel. DETAILED DESCRIPTION

[0038] Figure 1 A container handling system is shown, comprising a conveyor device (not shown in detail) for conveying containers 1, wherein in the present case, the containers 1 are so-called preforms, which are arranged in a blow mold 3 and formed into beverage bottles by introducing air via a blowing unit 4 arranged above the blow mold as part of a handling device 2. Furthermore, the blow mold 3 also serves as a container receiving device for the conveyor device, since the containers 1 are simultaneously moved during the conveying process.

[0039] according to Figure 1 The container 1 is arranged in a blow mold 3 and rests in the head region against a valve block of a blow unit 4. The valve block has a blow channel 5 through which compressed air can be introduced into the interior of the container 1. As a result, the container 1 expands and is pressed into the mold contour 6 formed in the blow mold 3. A stretch rod 7 is also provided, which is gradually inserted into the container 1 in the longitudinal direction L, thereby stretching the container 1.

[0040] The introduction of compressed air is achieved through individual valves and air channels. Figure 1These valves and air passages are not shown in further detail.

[0041] To monitor the machine state and / or operating status, a first acoustic sensor 8a and a second acoustic sensor 8b are provided. The first acoustic sensor 8a is arranged in the blowing channel 5, while the second acoustic sensor 8b is arranged in the stretch rod. Thus, the two acoustic sensors 8a and 8b are arranged in different operating positions and can, in particular, detect the sound generated by the fluid flow caused by the compressed air. Furthermore, it is also possible for the acoustic sensors 8a and 8b to detect structure-borne noise from individual system components.

[0042] The acoustic signal is preferably detected continuously throughout the entire blow molding process, in particular by Figure 2 The comparison can clearly derive the exact position of each acoustic sensor 8a, 8b.

[0043] The measured signal is sent to an evaluation unit 9, which includes a memory unit 10 in which reference signals characteristic of the machine state and / or operating state are stored. The evaluation unit 9 can examine the sound intensity and / or frequency of the sound signal. It can also determine signal patterns in the sound intensity and / or frequency. After comparison with the reference signal, a characteristic machine state and / or operating state can be determined and a signal is sent to an output unit 11. This output unit 11 then outputs a signal to a user in an optical and / or acoustic form, allowing the user to remain informed of the machine state and / or operating state.

[0044] Furthermore, the acoustic signals measured by the acoustic sensors 8 a , 8 b may be compared with each other, and then one of the two acoustic sensors 8 a , 8 b may measure a reference signal.

[0045] Reference Signs List

[0046] 1 container

[0047] 2 Processing equipment

[0048] 3 Blow mold

[0049] 4 Air blowing unit

[0050] 5 Air blowing channel

[0051] 6 Mold outline

[0052] 7 Tensile rod

[0053] 8a, 8b acoustic sensors

[0054] 9 Analysis and Evaluation Unit

[0055] 10 storage units

[0056] 11 Output Unit

[0057] L Longitudinal direction

Claims

1. A method for monitoring a container handling system comprising a conveying device for conveying containers (1), in particular beverage containers, and comprising at least one handling device (2) assigned to the conveying device for handling the containers (1) during the conveying process, Its characteristics are: During operation of the processing system, an acoustic signal is detected and compared with at least one reference signal to determine a machine state and / or an operating state.

2. The method according to claim 1, wherein: The acoustic signal is acoustic intensity and / or acoustic frequency.

3. The method according to any one of the preceding claims, characterized in that: The reference signal defines an upper limit value and / or a lower limit value.

4. The method according to any one of the preceding claims, characterized in that: The reference signal is a characteristic signal pattern that represents the state and / or operating state of the machine.

5. The method according to any one of the preceding claims, characterized in that: The reference signal is a characteristic signal pattern that characterizes deviations in the machine state and / or operating state.

6. The method according to any one of the preceding claims, characterized in that: The reference signal is stored in the evaluation unit.

7. The method according to any one of claims 1 to 5, characterized in that: In the first operating position, an acoustic signal is detected, and in the second operating position, a reference signal is detected.

8. The method according to any one of the preceding claims, characterized in that: The measured acoustic signal is generated by the fluid flow and / or structure-borne noise passing through system components.

9. The method according to any one of the preceding claims, characterized in that: The containers (1) are subjected to a treatment in the at least one treatment device (2), wherein the type of treatment is selected from the group consisting of blow molding, stretch blow molding, container sorting, container filling and / or container labeling.

10. A container treatment system for carrying out the method according to claim 1 , comprising a conveyor device for conveying containers (1), in particular beverage containers, and at least one treatment device (2) for treating the containers (1), arranged at least partially along the conveyor device, Its characteristics are: A monitoring device is provided for detecting and analyzing and evaluating sound signals.

11. The container processing system according to claim 10, characterized in that: The monitoring device comprises at least one acoustic sensor (8a, 8b) and an evaluation unit (9) connected to the at least one acoustic sensor (8a, 8b).

12. The container processing system according to claim 11, characterized in that: The at least one acoustic sensor (8a, 8b) is assigned to a processing device (2) and / or a conveying device.

13. The container processing system according to any one of claims 10 to 12, characterized in that: The processing device (2) is designed as a blow-molding station for blow-molding preforms into beverage containers.

14. The container processing system according to claim 13, wherein: The blow molding station has a blow channel (5) for introducing blow molding air into the preform, and at least one acoustic sensor (8a) is arranged in the blow channel (5), or at least one acoustic sensor (8a) is indirectly or directly connected to the blow channel (5) by sound conduction.

15. The container processing system according to claim 10 or 14, characterized in that: The blow moulding station has a stretching rod (7) in which at least one acoustic sensor (8b) is arranged.

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