Dynamic creation of switching processes and action instructions for machines

Abstract

The invention relates to a method and a system for dynamically creating action instructions for operator-guided switching of a machine production line, in particular in a machine production line for filling and packaging food and / or beverages, and to a machine production line. By means of the method and system of the invention, an efficient transition from a first device configuration to a second device configuration can be achieved, which is individually matched to the number of workers participating in the transition.

Description

[0001] The present invention relates to a method and system for dynamically creating operator-guided switching machine production lines, particularly in machine production lines for filling and packaging food and / or beverages, and a machine production line.

[0002] Modern production lines for manufacturing and / or packaging goods, such as filling equipment for filling and packaging food and / or beverages, are no longer designed as static systems for this limited purpose. Instead, the modularity of individual machine components allows the entire equipment to be individually transitioned from one state to another with manageable costs.

[0003] For example, in the beverage filling equipment industry, a first equipment configuration for filling 0.5-liter disposable PET containers can be converted to a second configuration suitable for filling 1-liter reusable containers with manufacturer-provided guidance. For these conversions or switchovers, machine production line manufacturers typically provide detailed documentation or guidance in the form of assembly or installation instructions, allowing customers to perform these conversions even without the manufacturer's service technicians.

[0004] The traditional practice for providing these assembly or installation instructions for switching from one configuration to another is to provide static instructions, which are directed to a specific number of people involved in the assembly or switchover process. These instructions may be provided in print or digitally via various media, including websites, mobile applications, and PDFs.

[0005] These traditional guidelines assign steps to a single person or a predetermined number of people required for the transition process. These assumptions are often based on average skills and abilities, which can lead to the effective implementation of the guidelines deviating from the actual situation and capabilities of the people involved.

[0006] Furthermore, traditional guidelines do not take into account the dynamic and variable nature of actual situations, where the number of people involved may vary. They do not provide the flexibility to adjust guidelines based on available resources. If the actual number of available personnel differs from the number specified in the guidelines, this can lead to inefficient switching processes.

[0007] Another technical drawback is that these guidelines do not handle task allocation and coordination among the personnel involved in an optimal way. They do not take into account individual skills, experience, and preferences, nor do they effectively allocate tasks to minimize the total time of the switchover process.

[0008] Therefore, there is a need for improved methods and systems for dynamically creating action instructions.

[0009] According to the present invention, this objective is achieved by the method of claim 1 and the system of claim 8. Embodiments and improvements are included in the dependent claims.

[0010] One embodiment of the present invention relates to a method for dynamically creating motion instructions for operator-guided changeover machine production lines, particularly in machine production lines for filling and packaging food and / or beverages. In this case, the method includes receiving a user request to create instructions for an operator-guided changeover process for changing the machine production line. The user request includes one or more boundary conditions. Examples of boundary conditions may be a selected number of operators or a selected time period. The number of operators executing the motion instructions during the operator-guided changeover process can then be determined. The determination of the number of operators is based on the boundary conditions. A set of motion instructions required for the operator-guided changeover process is then determined and divided by the specific number of operators. Finally, a specific number of instructions are created for the operators. The specific number of instructions corresponds to the specific number of operators, such that each of the specific number of instructions includes a portion of the set of motion instructions.

[0011] One embodiment of the present invention relates to a system for dynamically creating corresponding action instructions for operator-guided switching machine production lines.

[0012] Exemplary aspects of the invention are illustrated in the accompanying drawings. In the drawings: Figure 1 A diagram illustrating an overview of exemplary elements and basic structure of the present invention is shown; Figure 2 A diagram illustrating a user interface for interacting with a switching assistant according to the present invention is shown; Figure 3 Two exemplary portable display devices according to the present invention are shown, on which explicit action instructions for the respective users are displayed; Figure 4 An exemplary flowchart of a method for implementing a dynamic switching process according to the present invention is shown; Figure 5 An exemplary device configuration for PET containers and adhesive bundles is shown; Figure 6 An exemplary equipment configuration for PET containers and shrink packaging machines is shown; Figure 7 An exemplary device configuration for jars or glass bottles is shown; and Figure 8 An exemplary device configuration for a tank is shown.

[0013] Figure 1This is a diagram illustrating an overview of exemplary elements and basic structure of the present invention. According to one embodiment, these exemplary elements can be a first device configuration 100 switched by operator 115a-c to a second device configuration 102. The first device configuration 100 can be, for example, a beverage filling device including machine units 110a-c. Figure 1 As shown, the desired second device configuration 102 will no longer include machine units 110b and 110c from the first device configuration 100, but will include new or alternative machine units 110d-f.

[0014] Figure 1 The various modules 110 described herein are merely exemplary objects intended to illustrate the principles of the invention. (In conjunction with...) Figures 5 to 7 Various exemplary device configurations are illustrated. In principle, with the aid of the invention described herein, it is possible to build or switch back and forth between these different device configurations.

[0015] A variable number of operators 115a-c may be used for the conversion or switching, and these operators will be used for operator-guided switching processes. As described in more detail below, at least some of these operators may be equipped with electronic devices by means of which operators 115a-c are instructed with corresponding action commands, and then they execute those commands accordingly.

[0016] The accompanying drawings described herein typically illustrate three operators 115a-c by way of example. However, the invention is not limited to three operators, and any desired number of operators may be present, which precisely constitutes the flexibility of the invention, as described in more detail below.

[0017] The invention described herein is not necessarily limited to electronic media for displaying action instructions, and it is also conceivable that individual action instructions are created and provided to the user 115a-c (or at least some of them) in voice or paper form.

[0018] According to the present invention, the number of operators required for a switchover can be flexibly determined and notified to the system. Based on the specified number of operators, the system or computing unit 120 creates individual instructions for each specified operator, as described in more detail below.

[0019] As explained in more detail below, corresponding instructions with action commands are provided to the operator 115a-c by the computing unit 120. This computing unit 120 may be a manufacturer's cloud computing platform or a computer located closer to the device.

[0020] Several possibilities can be considered for the computing unit 120 to generate corresponding action instructions. In most cases, the equipment manufacturer has provided detailed but general conversion documentation. This documentation typically contains all the necessary steps required for the switch. According to some implementations, algorithms can be used to determine how to divide the individual action instructions in the manufacturer's documentation.

[0021] For example, action instructions can be evenly distributed among a specified number of operators. Alternatively, the dependencies between steps can be considered, and / or certain steps requiring more expertise can be assigned to experienced personnel.

[0022] For example, to divide individual action instructions, artificial intelligence can be used, which is specifically trained to optimize the combination of individual action instructions for a given number of operators.

[0023] As mentioned above, there are several methods to implement the division of individual action instructions. Generally, this is a matter of assigning action instructions from guidelines to the relevant operators in order to execute the setup effectively and correctly.

[0024] Dependency-based partitioning can consider the relationships and dependencies between various steps in the transformation process. For example, some tasks can only begin after other tasks have been completed. Computation unit 120 can identify and consider these dependencies in order to achieve optimized task allocation.

[0025] One way to represent these dependencies might be using graph theory. For example, in this case, a graph could be created where nodes represent individual tasks and edges represent dependencies between them. The direction of the edges determines the order of the tasks.

[0026] Artificial intelligence (AI) can also be used to interpret manufacturer-specified switchover instructions and optimize task allocation among any number of operators. Thus, for example, some tasks can be performed concurrently during a switchover, while others complement each other. Furthermore, some tasks may require more experience or expertise, while others can be performed by beginners.

[0027] Artificial intelligence can help break down and assign these tasks to specific operators. For example, AI can use natural language processing techniques to interpret a manufacturer's documentation. AI (or computing unit 120) can analyze the text of the manufacturer's documentation to identify different steps and understand which tasks must be performed. In this case, computing unit 120 can use machine learning algorithms to identify patterns and relationships between tasks. For example, computing unit 120 can determine that some tasks should always be performed in a specific order, or that some tasks should be performed simultaneously.

[0028] Based on this information, computing unit 120 can then perform optimal task allocation. This task allocation can be further improved by using optimization algorithms, where the total time of the switching process is minimized.

[0029] Figure 2 A diagram illustrating a user interface for interacting with a switching assistant according to an exemplary embodiment of the present invention is shown. Figure 2 The switching assistant dialogue shown can be, for example, part of a user interaction with computing unit 120, where the user sends a request to computing unit 120 for a desired conversion or switch in device configuration. During the interaction, it can be displayed... Figure 2 The dialog box prompts the user to define the corresponding boundary conditions. For example, these boundary conditions could be inputs from multiple operators that can be used for the transition. Alternatively, the boundary conditions could also be a time period used for the switching process.

[0030] like Figure 2 As shown, the calculation unit 120 can instruct on the time required for the switching process in parallel based on the number of operators involved. For example, in Figure 2 The diagram shows that if only one person performs the switch, the switchover process takes 2 hours and 20 minutes. When instructions are generated for two operators, the calculated required time is less than half that, i.e., within... Figure 2 In the example, it is only 58 minutes. Users can also specify the desired number of operators as a boundary condition in the bottom field (marked with "X"). Based on this instruction, the calculation unit 120 then calculates the time period required to switch to the user-specified number of operators. Conversely, users can also enter any desired time period in the lower right field, and the calculation unit 120 calculates / determines the number of operators required to comply with that time period (if possible), and accordingly creates a single guide with corresponding action instructions for that calculated number of operators.

[0031] Figure 3 Two exemplary portable display devices 330 and 340 are shown, displaying explicit action instructions for the respective users. Portable display devices 330 and 340... Figure 3 While shown as a smartphone, it can be any other form of electronic device suitable for issuing action commands to a user / operator. For example, action commands can also be issued via voice through a speaker. Other alternatives could be laptops, smart glasses, VR glasses, AR glasses, smartwatches, tablets, or other devices.

[0032] As an example, two portable display devices 330 and 340 display operator IDs 331 and 341, respectively. In this case, instruction 332, identified by operator ID "1" 331, should be displayed to the first operator to avoid confusion. The same applies to the second operator associated with device 340. Operator IDs 331 or 341 are particularly useful when multiple operators share a single display device. Two action instructions can then be displayed on that single display device, for example, on a split screen.

[0033] If an operator has successfully completed task 332 or 342, they can confirm by pressing the "Next" button. The progress can then be synchronized with other operators, which is particularly advantageous for interdependent tasks.

[0034] If the operator needs help, they can request it through the "Help" button.

[0035] As mentioned earlier, progress / status can be synchronized with other operators after each (partial) task is completed by one operator. In this case, synchronization between devices 330 and 340 (and other devices) of the operators involved is meaningful for ensuring effective collaboration and a smooth workflow. Various transitions are possible for synchronization.

[0036] For example, all display devices 330, 340 can be connected to a central server (e.g., but not limited to computing unit 120) that tracks the current status of each step. When a step is completed, this information can be sent to the server, which then updates all other display devices. Thus, each operator can know when the next step can begin.

[0037] Another possibility is direct synchronization between display devices without a central server. Each display device can send its state directly to all other display devices. This could be accomplished, for example, via Bluetooth, WLAN, or similar technologies.

[0038] The display device can be customized to send notifications when a step is completed and the next step can begin. These notifications can be displayed visually on the screen or output as an audio signal.

[0039] Figure 4An exemplary flowchart of a method for implementing a dynamic switching process according to the present invention is shown. The method involves a master user 415 (e.g., an administrator, supervisor, or foreman, etc.), a calculation unit 120, and (e.g.) three operators 115a-c. It should be noted that the master user 415 may also be one of the operators 115a-c. Furthermore, it should be noted that the number of operators shown in this example (i.e., three operators) is merely exemplary and may be fewer or more.

[0040] The method begins with step S1, in which the master user 415 sends a user request to the computing unit 120 to generate instructions for an operator-guided switching process for switching machine production lines. The user request may include one or more boundary conditions. Examples of boundary conditions may be a selected number of operators or a selected time period.

[0041] In step S2, the calculation unit 120 determines the number of operators executing action instructions during the operator-guided handover process. The number of operators is determined based on one or more boundary conditions. For example, if the boundary conditions include a selected number of operators, the calculation unit 120 determines the number of operators executing action instructions during the operator-guided handover process to be equal to the number selected in the boundary conditions. Optionally, if the boundary conditions include a selected time period available for the handover time, the calculation unit 120 determines the number of operators executing action instructions during the operator-guided handover process based on the handover time.

[0042] Furthermore, in step S3, the calculation unit 120 determines a set of action instructions required for the operator-guided switching process. For example, the set of action instructions may be adjusted based on a specific number of operators. For instance, additional steps may need to be added when a specific number of operators are unavailable.

[0043] In step S4, the calculation unit 120 divides the group action instruction into multiple specific operators and creates corresponding instructions for each operator. In this case, a specific number of instructions correspond to a specific number of operators. Each of the specific number of instructions includes at least a portion of the group action instruction.

[0044] After completing dynamic guidance and guidance dependent on the number of operators, it is finally transmitted from the computing unit 120 to the corresponding operators 115a-c, who can then continuously execute and confirm the corresponding tasks (A1, A2, A3, ...). As described above, the executed tasks can then be synchronized with other operators.

[0045] In the following Figures 5 to 8The present invention or at least some aspects thereof is described herein for various bottle filling equipment. Figures 5 to 8 The description is intended to provide only a general overview of machines that can collect state data, upon which LLMs can process user requests.

[0046] Figure 5 An exemplary device configuration 1000 for PET bottles or PET containers and adhesive bundling is shown. Figure 5 As shown, the equipment configuration includes 1000 different modules forming a line, at the end of which fully filled PET containers are distributed onto pallets in bundles. Some of the modules and machines may be optional, and the invention is not limited to the specific form and arrangement of the equipment configuration.

[0047] 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 made and shaped from initial materials. The produced PET containers are then conveyed to a filler 1010, where bottles are filled. The filler may optionally include a rinsing device. During storage or transportation, various particles, such as dust, cardboard, or wooden pallet residue, may accumulate in the preforms. These particles can be removed using the rinsing device. A sealing machine may be arranged at the end of the filler to seal the PET containers after filling.

[0048] Optionally, the equipment configuration 1000 may include a rotating device after the filling machine 1010 for hot filling of PET containers. The filled PET containers are conveyed to a separator 1020 and then to a drying unit 1024 via one or more conveyor belts 1016 (which may also include a buffer 1018 for intermediate loading of filled containers), where the PET containers are dried.

[0049] After drying, the PET containers are conveyed to labeling machine 1026. Labeling machine 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 handle applicator via second drying unit 1028, production line distributor 1030, conveyor belt 1032, adhesive bundle production device 1034, and curing path. In adhesive bundle production device 1034, PET containers are grouped together in specific bundle sizes and packaged into bundles, such as "six-packs". In handle applicator, handles are attached to the containers, making it possible to comfortably carry the bundles. The finished bundles are then correspondingly arranged into layers by robot 1042 and packed on pallets by palletizer 1044.

[0050] In equipment configuration 1000, so-called format carriages or format racks can be arranged at various modules and machines to provide quickly changeable format kits for short changeover times and automated tool switching. Examples of format carriages are format carriage 1006 for blow molding machine 1008, format carriage 1012 for filling machine 1010, format carriage 1022 for labeling machine 1026, format carriage 1038 for adhesive bundling production device 1034, and format carriage 1046 for palletizer 1044.

[0051] Figure 6 Another exemplary device configuration 1100 for PET containers and shrink packaging machines is shown. The device 1100 in Figure 10 includes… Figure 5 The equipment configuration includes many modules and machines of 1000, but some differences exist. Therefore, for Figure 10, those already combined are omitted. Figure 5 The description of the module being described.

[0052] A significant difference between the two exemplary device configurations 1000 and 1100 is that the labeling machine 1126, with labeling module 1127, can be installed after the blow molding machine 1008 and before the filling machine 1008. For this purpose, device configuration 1100 may include up to six transport tracks 1150 into which PET containers can be extruded. After the PET containers have been correspondingly extruded into one of the six tracks 1150, they are conveyed to a film wrapping module 1152 and then to a shrink tunnel 1154.

[0053] Figure 7 An exemplary device configuration 1200 for jars or glass bottles is shown. Figure 6 The exemplary device configuration 1200 is again with Figure 4 and Figure 5 The device configurations 1000 and 1100 have some similarities, so the description of the device configuration is limited to the differences in device configuration.

[0054] like Figure 7 As shown, an exemplary device configuration may include two separate supplies. Figure 7 The first supply on the left shows a branch of cans, or optionally a branch of new reusable bottles. Here, the containers (i.e., cans or new bottles) are guided into the machine by the depalletizer 1302, where they are guided to the filling machine 1010 via a conveyor belt. Figure 6 The second supply on the right shows a portion of a reusable bottle being introduced into the equipment from a reusable sorting device (not shown).

[0055] In cases where used reusable bottles are introduced into device 1200 via a sub-branch for reusable bottles, the reusable bottles first pass through a cleaning or washing machine 1304. Another possible difference in the exemplary device configuration 1200 is the addition of a transshipment packaging machine 1306 after the labeling machine 1026. The transshipment packaging machine can sort bottles or cans into cardboard clip application devices or boxes, or both.

[0056] Figure 8 An exemplary device configuration 1300 for cans is shown, wherein elements already described in other device configurations are not described again. In device configuration 1300, cans are introduced from a can magazine 1402 containing cans into a depalletizer 1302. After the cans have passed through a filling machine and been filled, the cans are sealed by means of a sealing magazine 1404, and the cans are further conveyed along device 1400 via a conveyor belt, as described above.

[0057] If not required, the optional pasteurizer 1408 can be bypassed via bypass 1412. In pasteurizer 1408, freshly filled products can be pasteurized for preservation.

[0058] Compared to device configurations 1000, 1100, and 1200, exemplary device configuration 1300 shows different tanks for corresponding consumables, such as tank 1410 having rinsing liquid and / or filling product, and tank 1406 having lubricant. These tanks may also be included in the exemplary device configurations already described above. For example, chemical product 106 conveyed from mixer 110 to the machine may be stored in tanks 1406 and 1410.

Claims

1. A method for dynamically creating operator-guided switching machine production lines, particularly in machine production lines for filling and packaging food and / or beverages, wherein, The method includes: Receive a user request to create instructions for an operator-guided switching process for switching the machine production line, wherein the user request includes one or more boundary conditions; Determine the number of operators who execute action instructions during operator-guided switching, wherein the number of operators is determined based on one or more boundary conditions; Determine the set of action instructions required for the operator-guided switching process; The number of group action instructions assigned to specific operators; and Create a specific number of instructions, wherein the specific number of instructions corresponds to the specific number of operators, and wherein each of the specific number of instructions includes a portion of the group action instructions.

2. The method according to claim 1, wherein, The boundary conditions include a selected number of operators, wherein a specific number of operators executing action instructions during operator-guided switching is equal to the number selected in the boundary conditions.

3. The method according to claim 1, wherein, The boundary conditions include a selected time period that can be used for the switching time, and wherein the number of operators executing action instructions during the operator-guided switching process is determined based on the switching time.

4. The method according to any one of claims 1 to 3, further comprising: The created instructions are transmitted to one or more electronic display devices.

5. The method according to any one of claims 1 to 4, wherein, The group action instructions are adjusted based on the specific number of operators.

6. The method according to any one of claims 1 to 5, wherein, The group action instructions are determined by artificial intelligence.

7. The method according to any one of claims 1 to 6, wherein, Dividing the group action instructions into the specific number of operators includes: Consider the dependencies between individual action instructions; and / or Individual action instructions are categorized based on the qualifications required for the operator to execute them.

8. A system for dynamically creating operator-guided switching machine production lines, particularly for machine production lines used for filling and packaging food and / or beverages, wherein, The system includes: A computing unit having a user interface, wherein the computing unit is adapted to: The system receives user requests via the user interface to create instructions for an operator-guided switchover process for switching the machine production line, wherein the user request includes one or more boundary conditions. Determine the number of operators who execute action instructions during operator-guided switching, wherein the number of operators is determined based on one or more boundary conditions; Determine the set of action instructions required for the operator-guided switching process; The number of group action instructions assigned to specific operators; and Create a specific number of instructions, wherein the specific number of instructions corresponds to the specific number of operators, and wherein each of the specific number of instructions includes a portion of the group action instructions.

9. The system according to claim 8, wherein, The boundary conditions include a selected number of operators, wherein a specific number of operators executing action instructions during operator-guided switching is equal to the number selected in the boundary conditions.

10. The system according to claim 8, wherein, The boundary conditions include a selected time period that can be used for the switching time, and wherein the number of operators executing action instructions during the operator-guided switching process is determined based on the switching time.

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