Monitoring method for monitoring an unwinding process, unwinding device and unwinding system

Abstract

Monitoring method (100) for monitoring an unwinding process of an unwinding device (2), comprising the following steps: - At least partial unwinding (101) of a web material (11) from a roll (10), - Detecting (102) at least one irregularity (12) of the web material (11) and / or the unwinding process, - Determine (103) a correlation of the irregularity (12) to at least one running parameter (13) of the winding (10), wherein the running parameter (13) is determined by detecting a preferred parameter (51.1) on the web material (11), wherein the correlation of the irregularity (12) to the running parameter (13) is an assignment of a specific value of the running parameter (13) to a position of the irregularity (12) with respect to the coil (10) and / or vice versa.

Description

[0001] The present invention relates to a monitoring method for monitoring an unwinding process, an unwinding device for carrying out an unwinding process of a web material and an unwinding system.

[0002] To distribute a continuous material, such as manufactured film, to the point of use or distribution, it is often supplied in portions in the form of rolls. These rolls are first wound onto a winding device and then unwound at the point of use by an unwinding device. After unwinding, further processing often follows, such as the creation of plastic bags, wrapping stacked goods for load securing, or similar operations. However, errors can occur during the unwinding process. These errors can originate in the manufacturing process of the rolls, i.e., in the production of the film and / or during the winding process, or they can result from faulty unwinding. Therefore, it is desirable to detect such errors and, ideally, to be able to trace their cause.

[0003] It is also known from the prior art to save relevant data from a winding process with a timestamp in order to draw conclusions about the progress of production. However, a disadvantage of this is that the time stamp alone often only provides imprecise conclusions, as the exact winding parameters are unknown. For example, such windings are frequently labeled with a weight, but this does not allow for an exact determination of the actual thickness of the film material intended for the windings. Due to fluctuating film thickness, the calculation of the film diameter can also be inaccurate. Furthermore, air inclusions in the winding can cause further inaccuracies, making it impossible to reliably determine the position of the relevant data within the winding.

[0004] Further procedures for settlement processes are known from the documents DE 10 2015 213 709 A1, DE 198 82 374 B4, DE 10 2009 029 083 A1 as well as DE 602 13 294 T2 and EP 2 847 115 B1.

[0005] It is an object of the present invention to at least partially overcome the aforementioned disadvantages known from the prior art. In particular, it is an object of the present invention to improve the reliability and / or accuracy of inferences about the manufacturing process of a winding from an unwinding process.

[0006] The foregoing problem is solved by a monitoring method having the features of claim 1 and an unwinding device having the features of claim 12 and an unwinding system having the features of claim 17.

[0007] Further features and details of the invention will become apparent from the dependent claims, the description, and the drawings. Features and details described in connection with the monitoring method according to the invention naturally also apply in connection with the unwinding device and / or the unwinding system according to the invention, and vice versa, so that the disclosure regarding the individual aspects of the invention always refers to each other.

[0008] According to the invention, the monitoring method for monitoring an unwinding process of an unwinding device comprises at least the following steps: - At least partial unwinding of a web material from a roll, - Detecting at least one irregularity in the web material and / or the unwinding process, - Determining a correlation between the irregularity and at least one running parameter of the winding.

[0009] The roll can preferably be supported on a winding holder during unwinding. The roll comprises, in particular, a winding core and at least a portion of the web material. During unwinding, the web material is reduced on the roll and preferably fed to a further processing station. Preferably, the web material comprises a plastic film. Plastic films have a complex manufacturing process in which many parameters may need to be considered, making information exchange between individual processes particularly advantageous for plastic films. Additionally or alternatively, other materials are conceivable for the web material. The detection of at least one irregularity in the web material and / or the unwinding process can be carried out, in particular, using sensors or computational methods. For example, a detection unit can be provided to identify an irregularity.Preferably, the irregularity can be detected optically and / or acoustically. For example, the detection unit can be designed to detect the irregularity using ultrasound and / or include a camera. Furthermore, it is conceivable that the irregularity is detected electronically and / or computationally, for example by measuring the current required by a drive element or the like, in order to determine the drive power. An irregularity can be understood, in particular, as a critical or non-critical feature in the processing during unwinding. Thus, the irregularity can preferably include a defect present in the web material. The irregularity can, for example, include at least one of the following features: - Unsuccessful opening of a hose of the track material, - Breaking down a product made from railway material, - Tearing of the track material, - Missing at least part of a printed image on the web material, - Increased slippage at a drive element during the unwinding of the web material, - Changes in torque and / or forces during the processing of the web material.

[0010] Thus, the irregularity can directly or indirectly affect the web material and / or the unwinding process. For example, the web material may be wound as a tube, which is opened during or after unwinding, so that a three-dimensional shape emerges from a previously folded tube. Furthermore, it may be observed that the web material, for example, cannot withstand the processing into bags, and the resulting bag tears. Such tearing can also occur during or shortly after unwinding, thus representing a potential irregularity. Additionally, the web material may have a printed image. For example, to manufacture plastic bags, the web material may be printed before being wound. If part of this printed image is missing, e.g.,A lack of ink in a printer unit can be detected as an irregularity in the unwinding process. Furthermore, a change in slippage during the unwinding of the web material can be understood as a situation where a drive mechanism responsible for propelling the web material is at least partially slipping. In this case, the speed of the drive and the speed of the web material will differ accordingly. Additionally, forces and / or moments can be measured at various points during the unwinding process, which can indicate the occurrence of an irregularity.

[0011] The running parameter can preferably also be referred to as running meters. In particular, the running parameter can encompass the actual unwound length of the web material from the coil to the occurrence of the irregularity. This length can be related to the irregularity in various ways, i.e., correlated. For example, the running parameter can encompass a length extending from the starting point of the web material, i.e., from the first unwound end of the web material, to the beginning of the irregularity, to the end of the irregularity, or to an average value between the beginning and end of the irregularity. The correlation of the irregularity to the running parameter thus refers to the assignment of a specific value of the running parameter to a position of the irregularity relative to the coil and / or vice versa.In particular, the running parameter is thus correlated or interrelated with the irregularity. If the irregularity includes, for example, the absence of a printed image, the running parameter can encompass the length from the start of the web material's unwinding until the beginning of the absence of the printed image and / or until the end of the absence of the printed image. Furthermore, the running parameter can encompass the length of the unwound material until the irregularity occurs in the form of a specific event, such as a change in forces and / or moments. The correlation between the irregularity and the running parameter can therefore be understood as relating the irregularity, especially its occurrence, to the running parameter.This can be achieved, for example, by providing a table with at least two columns, where the irregularity is entered in the first column and the run parameter or a value of the run parameter in the second column of the table, so that it is possible to trace at which position in the loop the irregularity occurred. In particular, a field variable of a computer program can also be used instead of the table, or the table can be provided directly. This makes it particularly clear that the irregularity is assigned to a value of the run parameter, i.e., occurs at a specific position within the run parameter. A cluster of irregularities in a specific range of the run parameter can also be determined in this way.

[0012] The monitoring method according to the invention makes it possible to determine the position of the irregularity in the winding. This allows conclusions to be drawn about errors in the winding process and / or during the unwinding of the winding. For example, a frequent occurrence of an irregularity in the core of the winding may indicate that it was wound with excessive tension. This allows the winding process to be improved. Furthermore, it is possible to assess whether the irregularity arose due to an error in the unwinding process. This can be relevant, for example, in warranty cases, when the question arises whether the winding had a defect when it was delivered to a customer or whether the defect only arose due to improper handling of the winding.The monitoring method according to the invention can provide a further indicator relevant to the question of proof. Therefore, the monitoring method can also include the following step: - Evaluating the correlation between the irregularity and the running parameter.

[0013] The evaluation can also be performed automatically, for example, based on predefined criteria, particularly by a processing unit. This allows for an automatic conclusion to be drawn about the cause of the irregularity within the process, ensuring reproducible accuracy. Specifically, by using the winding's running parameter, the parameter is referenced to that specific winding, so the conclusions can be attributed to a particular winding in relation to its production.

[0014] Within the scope of the invention, it is further conceivable that the running parameter is determined during the unwinding of the web material from the reel. Preferably, the running parameter can be determined continuously during the unwinding of the web material from the reel. The determination of the running parameter can include direct measurement of the running parameter. The running parameter can thus, for example, be continuously recorded and logged during unwinding, so that a value corresponding to the irregularity is immediately available when it is detected. Alternatively, the running parameter can also be determined non-continuously during unwinding, for example, by measuring the running parameter only when an irregularity is detected. Continuous measurement of the running parameter can include analog and / or digital measurement. Thus, a detection means for acquiring the running parameter can operate incrementally and...For example, a signal can be output after a certain length or revolution, from which the running parameter can be deduced. By recording the running parameter during unwinding, it is not necessary, for example, to measure it manually, so that the monitoring process can be further automated, thus saving costs and simultaneously ensuring reproducible, high accuracy.

[0015] The running parameter is determined by measuring a drive parameter on the web material. Preferably, a measurement of the winding's rotational speed can also be performed. The drive can be understood as a part of a drive element that acts on the web material to enable it to propel itself. A drive parameter can include a speed, in particular a rotational speed and / or tangential speed of a drive roller, at the drive. The measurement of the drive parameter can be directly related to the actual unwound length and is therefore a high-quality indicator of the running parameter. At the drive, the web material already runs in a flat plane, so that correspondingly varying winding diameters at the drive have no or only a minor influence.Preferably, the running parameter can be determined by measuring the pre-winding parameter and the winding speed. Measuring the winding speed allows for a correction of the pre-winding parameter, preferably also including an estimate of the winding diameter. Thus, the actual measurement of the running parameter can be performed on the pre-winding unit, but this measurement can be corrected based on the winding speed measurement to at least partially compensate for slippage at the pre-winding unit. This results in a high degree of accuracy in determining the running parameter, thereby improving the accuracy of deducing the cause of the irregularity.

[0016] Furthermore, in a monitoring method according to the invention, it is conceivable that the monitoring method further comprises the following step: - Entering the correlation between the irregularity and the running parameter into a database

[0017] A database can preferably be understood as an electronic table. For example, an SQL server can be stored on a storage medium, providing a corresponding database. In particular, the correlation between an irregularity and a run parameter can be determined by linking the irregularity and the run parameter in such a way that they can be assigned to each other when entered into the database. Furthermore, the database can be accessed, for example, after the processing operation or at another time, and the correlation between the irregularity and the run parameter can be traced. This allows, for instance, several irregularities to be evaluated together after the completion of a processing operation, or several irregularities from several different processing operations to be evaluated together.For example, a conclusion can only be drawn by examining several coils from a batch together for irregularities using the database, so that a pattern only emerges when examining multiple coils. Thus, entering the irregularity and the running parameter into a database also improves the possibility of drawing conclusions about the related processing or manufacturing processes from the data obtained.

[0018] Furthermore, in a monitoring method according to the invention, it is conceivable that when the correlation is entered into the database, the irregularity is correlated with a time value and then further correlated. Thus, for example, a first correlation with the running parameter can be determined, and a second correlation with time can be generated or determined. The time value can be a specific time, in particular a specific time, of the occurrence of the irregularity. For example, the time value can be provided as a third column in a table of the database. By recording the time of the irregularity's occurrence, the conclusions that can be drawn from it can be further improved.For example, it is possible to estimate whether irregularities occur more frequently in a particular operator's shift than in another shift, thus identifying operator errors during the unwinding process. Furthermore, the time stamp can indicate a connection between the occurrence of the irregularity and another event during the unwinding process, such as a power outage. This results in several correlations between the irregularity, the time stamp, and the running parameter, providing further information about the handling of a specific reel during processing. In particular, the transverse position of the irregularity can be determined in correlation with the running parameter, allowing for further insights into the cause of the irregularity.

[0019] Within the scope of the invention, the database can advantageously be provided on a server and / or an internal storage unit of the unwinding device. An external server can be understood as a computing unit that has storage capacity for the database and is located outside the unwinding device. For example, the external server can be part of a palletizing system or located externally at a service provider. In this way, data storage can be outsourced, for example, to utilize the capacities of a computing power and / or storage provider, thereby reducing the costs of the unwinding device. The unwinding device can, for example, simply have a communication interface, enabling it to communicate with the database on the external server.Furthermore, the external server can, for example, be connected to or be part of a winding device, allowing data about the coils being processed to flow directly back to the coil manufacturing process. Additionally or alternatively, the database can be stored on an internal storage unit and / or a mobile storage unit. For instance, the unwinding device itself can include a corresponding storage unit, such as an internal HDD or SSD, making the generated data directly available at the unwinding device. A mobile storage unit offers the advantage of being connected to the unwinding device via a USB interface, for example, while the data is being transferred, and then being easily transportable to make the data available to, for example, a development department.

[0020] Within the scope of the invention, it is also conceivable that the monitoring method further comprises the following step: - Visual and / or audible output of a warning message when the irregularity is detected or the irregularity is of a predefined irregularity type.

[0021] The warning message can, for example, inform an operator of the unwinding device about the occurrence of an irregularity, allowing them to initiate appropriate countermeasures or reaction measures. The warning message can be displayed, for instance, via a warning light or a screen. Additionally or alternatively, an acoustic signal, such as a warning tone from a loudspeaker, is also possible. A predefined irregularity type could mean, for example, that a specific type of web material defect is particularly critical and therefore requires a warning message, while other types of web material defects are simply recorded and correlated with the running parameters.For example, a change in slippage at the pre-seed may be non-critical and therefore not require any warning messages, but a missing print image may require that correspondingly manufactured subsequent products be sorted out or that the unwinding process be interrupted.

[0022] Furthermore, in a monitoring method according to the invention, it may be provided that the monitoring method comprises the following step: - Visualizing the correlation between the irregularity and the running parameter.

[0023] Visualization can be achieved, for example, on a display showing a diagram plotting the occurrence of irregularities against running parameters. This allows an operator of the unwinding device to see, for instance, a cluster of irregularities within a specific running parameter range, enabling them to draw conclusions from the correlation directly at the unwinding device. Therefore, the display is preferably located on the unwinding device. Alternatively, or additionally, the correlation between the irregularity and the running parameter can be visualized on a display outside the unwinding device.For example, the processing device can be configured to communicate with a network, allowing data to be transmitted to a monitoring station and / or directly to a development department for immediate evaluation. Visualization can thus simplify the monitoring process and, in particular, increase user-friendliness for those involved, ultimately saving time during evaluation.

[0024] Furthermore, in a monitoring method according to the invention, it is conceivable that the monitoring method further comprises the following step: - Determining the probability of a cause of the irregularity in a manufacturing process of the web material and / or in the unwinding process.

[0025] Thus, for example, a probability assessment can be automatically performed based on a cluster of irregularities within a specific running parameter or on the correlation of a single irregularity with that parameter. This eliminates the need for manual evaluation. A processing unit within the unwinding device can determine the probability and therefore output a reproducible result. Furthermore, this allows for further automation of the monitoring process, creating a standardized basis for determining the correlation or probability.

[0026] Within the scope of the invention, it can further be provided that the irregularity comprises a process parameter that lies outside a parameter range. For example, the parameter range can have at least one parameter limit above which the irregularity is defined. If the process parameter exceeds or falls below this parameter limit, an irregularity is assumed. The parameter limit can be absolute or relative. Preferably, two parameter limits are provided, defining a closed parameter range both above and below. Exemplary parameter limits could be the opacity of a printed image, the transparency of a film material, or a tolerable slippage at the feed point. These parameter limits can, as already described, be absolute, i.e., predefined or predefined at the beginning of the monitoring process.Additionally or alternatively, relative parameter limits can be provided, which, for example, define an irregularity in such a way that the process parameter is dynamically wound over a certain length during the unwinding process and a certain percentage above and / or below this value is considered an irregularity.

[0027] In a monitoring method according to the invention, it is also conceivable that the number of products produced from the web material is determined based on the running parameter. Preferably, the products can be bags made of plastic film. Thus, by using the running parameter and, in particular, by taking into account any irregularities in the web material that may not be processed, it is possible to calculate the total length and / or total area of ​​the web material. This, in turn, allows the number of products produced from a specific roll to be calculated. Compared to an estimate based on the weight of the roll, this method also has the advantage that the determination based on the running parameter is essentially or completely corrected for any fluctuating thickness of the web material.

[0028] The sequence of individual process steps of a monitoring method according to the invention can be carried out in the described order. However, a different sequence of process steps than the one described is also conceivable. In particular, individual process steps or all process steps can be repeated and / or carried out in parallel.

[0029] In particular, the problem is further solved by a quantification method for determining the number of products produced from a web material during an unwinding process of an unwinding device, comprising the following steps: - At least partial unwinding of the web material from a roll, - Recording at least one running parameter of the winding, - Calculating the number of products produced from the web material, in particular bags, based on the running parameter of the winding, in particular taking into account at least one irregularity of the web material and / or the unwinding process.

[0030] Thus, the quantification method could constitute a further aspect of the present invention. This offers the advantage that the determination based on the running parameter can be substantially or completely corrected for any fluctuating thickness of the web material. In particular, features and details described in connection with the monitoring method and / or the unwinding device and / or the unwinding system according to the invention naturally also apply in connection with the quantification method according to the invention, and vice versa, so that the disclosure relating to the individual aspects of the invention is always, or can always be, mutually referenced. In particular, the features of the characterizing part of the present dependent claims of the monitoring method according to the invention can also represent further developments of the quantification method.

[0031] According to a further aspect of the invention, an unwinding device for carrying out an unwinding process of web material from a coil is claimed. The unwinding process is monitored by a monitoring method according to the invention. The unwinding device has a coil holder on which the coil can be stored during the unwinding process. Furthermore, the unwinding device has a drive means by which a propulsion of the web material can be generated, and a detection unit by which at least one irregularity of the web material and / or the unwinding process can be detected. The detection unit is in communication with a processing unit, whereby the processing unit can determine a correlation of the irregularity to at least one running parameter of the coil.

[0032] The detection unit can be designed for optical and / or acoustic detection of the irregularity. For example, the detection unit can include a camera and / or an ultrasonic sensor. Furthermore, the detection unit can have means for measuring force and / or torque. Depending on the type of irregularity to be detected, the detection unit can be arranged on the drive element, the winding support, and / or a frame of the unwinding device. Depending on the application, other arrangements are also conceivable. The processing unit can also be part of a computer or control system. For example, a control unit of the unwinding device can include the processing unit. The drive element preferably comprises two driven rollers that are in contact with the web material, so that the web material is propelled when the drive element is driven.The drive element can have a particularly structured surface, through which the bias of the web material can be achieved via friction. The winding holder can preferably include a winding mandrel onto which the coil is pushed for the unwinding process, so that it is rotatably mounted on the unwinding device. Preferably, the detection unit and / or at least one measuring device for detecting the running parameter can be arranged on the winding holder.

[0033] Thus, an unwinding device according to the invention offers the same advantages as those already described in detail with reference to a monitoring method according to the invention. The detection unit can record the irregularity, and the processing unit can establish a correlation, which in particular improves the ability to infer the origin of the irregularity from its relationship with the running parameter. The running parameter can preferably be recorded by a measuring device and / or the detection unit and / or the processing unit. The correlation can be established by the processing unit, for example, by assigning the irregularity to the running parameter, e.g., by isolating one measured value and writing it to a table in a manner corresponding to the other measured value.Preferably, the computing unit can execute a computer program that establishes the correlation. Furthermore, the unwinding device, in particular the computing unit of the unwinding device, can be configured to execute a quantification method for determining the number of products produced from the web material.

[0034] In an unwinding device according to the invention, it is particularly conceivable that the unwinding device is designed for producing bags from the web material, especially from tubular and / or flat web material. For this purpose, the unwinding device can have at least one folding means for folding the bags and / or at least one closing means for closing the bags. The closing means can be designed to form a fold and / or weld the web material to close the bags. The folding means can include a guide by which the web material can be guided, particularly during advancement, in such a way that a bag shape is at least partially formed from the web material. Furthermore, the unwinding device can have at least one filling means by which bags produced from the web material can be filled.Thus, the unwinding device can be suitable for producing ready-to-ship bags from the web material and / or filling products, in particular so that the entire bag manufacturing process, from the delivery of the raw material (e.g., web material and filling products), can be mapped by the unwinding device. By detecting one or more irregularities, rejects can be reduced and / or the delivery of defective bags can be avoided. Preferably, the unwinding device therefore comprises a so-called FFS machine, where FFS stands for "Form, Fill and Seal".

[0035] Within the scope of the invention, it is further conceivable that the computing unit is in communication with a measuring unit for detecting a preferred parameter of the web material. In particular, the measuring unit can also be configured to measure the rotational speed of the winding. The measuring unit can be part of the detection unit or form an independent component within the unwinding device. For example, a measuring device can be provided for measuring the rotational speed of a drive element. The rotational speed can, in particular, include an angle of rotation. Furthermore, the drive element can have at least one drive roller which, by rotation, propels the web material forward by means of friction and has a fixed diameter. The actual advance of the web material can then be determined by the measuring unit and / or the computing unit using the rotational speed and the diameter.This can preferably be corrected by measuring the number of revolutions to achieve increased accuracy. This provides a simple way to determine the actual feed rate of the web material and thus the running parameter, where the diameter of the winding plays no or only a minor role.

[0036] Preferably, the processing unit can perform a calculation of the running parameter. For example, the calculation can be based on a measurement of the lead of the web material and, in particular, a measurement of the winding speed. The winding speed can thus be used, for instance, to account for slippage at the lead in the calculation, thereby improving the accuracy of the calculated result or the measurement result at the lead.

[0037] In an unwinding device according to the invention, the computing unit can advantageously have a communication interface for data communication with a database, so that the correlation of the irregularity to the running parameter can be entered into the database via the communication interface. The communication interface can include a network connection or the like for wired transmission from the computing unit to the database. Additionally or alternatively, the communication interface can enable wireless communication and, for example, include a WLAN unit. Furthermore, the database can be provided on a storage medium, which can, for example, be part of the unwinding device. This allows the computing unit to communicate directly with the storage unit, for example, via an internal wired connection.The storage unit can contain a computer program for carrying out a monitoring procedure and / or for establishing a correlation between running parameters and irregularities. The database can therefore be located on an external server and / or on an internal storage unit of the winding device. Additionally or alternatively, the database can be stored on a portable storage unit. For example, the communication interface could be a USB interface, allowing an external hard drive to be connected to the processing unit, thus making the database portable. The database allows multiple irregularities and running parameters to be correlated and simultaneously retrieved at a later time to identify specific patterns.

[0038] It is also conceivable that, in an unwinding device according to the invention, the computing unit is in communication with an output unit and is configured to issue a visual and / or acoustic warning message via the output unit when an irregularity is detected or the irregularity is of a predefined type. The output unit can, for example, include a display, a light, and / or a loudspeaker to display or issue the warning message. A warning message thus informs an operator of the unwinding device, so that it is not necessary for the operator to constantly monitor the unwinding device, but they are nevertheless informed via the output unit when a problem or a process-relevant event occurs.

[0039] According to a further aspect of the invention, an unwinding system for carrying out an unwinding process of web material from a coil is claimed. The unwinding process is monitored by a monitoring method according to the invention. The unwinding system further comprises an unwinding device, which is preferably an unwinding device according to the invention. The unwinding device has a coil holder on which the coil can be stored during the unwinding process, a drive means by which a propulsion of the web material can be generated, and a detection unit by which at least one irregularity of the web material and / or the unwinding process can be detected. The detection unit is in communication with a computer unit, whereby a correlation of the irregularity to at least one running parameter of the coil can be determined by the computer unit.

[0040] Thus, an unwinding system according to the invention offers the same advantages as those described in detail with reference to an unwinding device and / or a monitoring method according to the invention.

[0041] Preferably, in a processing system according to the invention, an external server with a database can be provided, which is in communication with the processing unit, so that the correlation of the irregularity to the running parameter can be entered into the database via the communication interface. This allows the processing system to be distributed across multiple locations, thus structurally decoupling the server from the processing device, at least partially. The server can be located at an external service provider, so that, for example, several processing devices can communicate with the same server. This can save costs if the server is not part of the processing device, and it also allows multiple processing devices to use the same database to draw conclusions about the causes of, for example, recurring irregularities with improved accuracy.Irregularities and running parameters, or their correlation, can also be evaluated externally in order to draw conclusions. Based on these findings, the manufacturing process for web material and / or winding processes can then be improved.

[0042] Further measures improving the invention will become apparent from the following description of some exemplary embodiments of the invention, which are schematically illustrated in the figures. All features and / or advantages arising from the claims, the description, or the drawings, including design details, spatial arrangements, and process steps, can be essential to the invention, both individually and in various combinations. It should be noted that the figures are for descriptive purposes only and are not intended to limit the invention in any way. They show: Fig. 1: an unwinding system according to the invention with an unwinding device according to the invention in a schematic top view in a first embodiment; Fig. 2: an unwinding system according to the invention with an unwinding device according to the invention in a second embodiment in schematic top view; Fig. 3: a monitoring method according to the invention in a schematic representation of the method steps in a third embodiment; Fig. 4 ae: a further, schematic representation of process steps of the monitoring procedure of the third embodiment, Fig. 5 ac: Examples of irregularities within a processing procedure.

[0043] In the following figures, identical reference numerals are used for the same technical features even for different embodiments.

[0044] Fig. Figure 1 shows an unwinding system 5 according to the invention for carrying out an unwinding process of a web material 11 by means of an unwinding device 2. The unwinding device 2 comprises a winding holder 70 on which a coil 10 can be stored, or is stored during the unwinding process. The coil 10 comprises a winding sleeve 10.1 and at least partially a web material 11. During the unwinding process, the web material 11 is unwound from the coil 10 in a substantially planar fashion. The winding holder 70 is designed to rotatably mount the coil 10 so that the coil 10 rotates accordingly during the unwinding of the web material 11. A drive means 50 is also provided to achieve a propulsion 11.1 of the web material 11.The drive element 50 can, for example, be designed to rotate the coil 10 and / or include a drive roller 51 which rolls the web material 11 to pull the web material 11 off the coil 10. It is also possible, for example, for the coil 10 to be mounted only rotatably on the coil holder 70, so that the rotation can be achieved by the drive rollers 51. Furthermore, a detection unit 20 is provided, by which at least one irregularity 12 of the web material 11 and / or the unwinding process can be detected. The irregularity 12 is in . Fig. 1 is represented as the absence of a printed image. The detection unit 20 therefore comprises a camera for optically detecting the web material 11 and the irregularity 12. Furthermore, a measuring unit 21 is provided, by which the advance 11.1 of the web material 11 can be detected and a rotation number 11.2 of the winding 10 can be measured. The detection unit 20 and the measuring unit 21 are in communication with a processing unit 30, so that a correlation between the irregularity 12 and a running parameter 13 can be determined by the processing unit 30. Thus, the running parameter 13 can, for example, include a length of the unwound web material 11 up to the irregularity 12 and / or a length of the web material 11 up to the end of the irregularity 12. This allows the position of the irregularity 12 on the web material 11 in relation to the winding 10 to be determined.The computing unit 30 further comprises a communication interface 31 for entering the irregularity 12, in correlation with the running parameter 13, into a database 40. The database 40 is provided as part of an internal storage unit 41 of the unwinding device 2 and is preferably directly connected to the computing unit 30 via the communication interface 31 by means of a cable. A computer program can preferably be executed by the computing unit 30, which establishes the correlation between the irregularity 12 and the running parameter 13. Preferably, the correlation can be established by the computing unit 30 entering the running parameter 13 and the irregularity 12 into the database 40 in a way that allows for their mutual assignment. The correlation allows conclusions to be drawn about the manufacturing process of the coil 10 and / or the unwinding process. In particular, the irregularity 12 can be located within the coil 10.The occurrence of a specific irregularity 12 in the core can, for example, indicate that the roll 10 has been wound too tightly. Furthermore, the processing unit 30 is in communication with an output unit 60, so that a visual and / or audible warning message can be issued via the output unit 60 if the irregularity 12 is detected or if the irregularity 12 is of a predefined irregularity type. For example, the irregularity 12 can be defined such that a printed image is missing over a certain length of the web material 11, in which case a warning message is issued to the output unit 60. The output unit 60 can include various output devices for issuing the warning message. For example, a light source 62 and / or a loudspeaker 63 can be provided for issuing the warning message.Preferably, the output unit 60 further comprises a display 61 on which, firstly, various parameters of the unwinding process can be displayed and, secondly, the warning message can be output. Instead of the absence of the printed image, other types of irregularities are possible. For example, different types of irregularities can also be detected by the detection unit 20. Furthermore, the detection unit 20 can, for example, additionally or alternatively include measuring means for measuring a force or torque of the winding 10 and / or the web material 11. Further exemplary types of irregularities are described in the [references to be added]. Fig. Figures 5a to 5c are shown. Preferably, the computing unit 30 can also determine the number of products produced from the web material 11, so that this number can be determined based on the running parameter 13 instead of by counting, and thus the number can be assigned to the roll 10. In particular, a quantification method for determining the number of products produced from the web material 11 can therefore be carried out by the unwinding device 2 of the unwinding system 5.

[0045] Fig. Figure 2 shows an unwinding system 5 according to the invention for carrying out an unwinding process of a web material 11 from a coil 10. The unwinding system 5 corresponds to the Fig. 2 of the second embodiment essentially corresponds to the unwinding system 5 of the first embodiment. However, instead of an internal storage unit of an unwinding device 2 of the unwinding system 5, an external server 42 is provided, which has a database 40. The server 42 is in communication with a processing unit 30, so that a correlation of an irregularity 12 to a running parameter 13 can be entered into the database 40 via a communication interface 31. The communication interface 31 can, for example, include internet access, which can be wired and / or wireless. Thus, the unwinding device 2 can, for example, include a SIM card to establish a communication connection with the external server 42.Because the external server 42 is outsourced, several processing devices 2 can communicate with the server 42 to concentrate the collected data and, if necessary, correlate it. This allows for further insights into the occurrence of irregularities and / or improves the accuracy of the resulting conclusions. Furthermore, the external server 42 can be cost-effective for the processing device 2, as it does not, for example, contain the database 40 itself, thus eliminating the need for an additional internal storage unit or allowing it to be used for redundancy to improve data security. In particular, the processing system 5 can also be used according to... Fig. 2. A quantification procedure for determining the number of products produced from the web material 11 must be feasible.

[0046] Fig. Figure 3 shows a monitoring method 100 according to the invention for monitoring an unwinding process of an unwinding device 2 in a further embodiment in a schematic representation of the method steps. The monitoring method 100 comprises at least partial unwinding 101 of a web material 11 from a coil 10, as is also described in Fig. Figure 4a illustrates this. The propulsion 11.1 can, for example, be achieved by a drive means 50 of an unwinding device 2. Furthermore, the monitoring method 100 includes the detection 102 of at least one irregularity 12 of the web material 11 and / or the unwinding process. Thus, when the web material 11 is unwound from the reel 10, a detection unit 20 can determine that a specific process parameter deviates. This could, for example, be the fading of a printed image, so that the area of ​​the irregularity 12 is detected as such. Furthermore, the determination 103 of a correlation between the irregularity 12 and at least one running parameter 13 of the reel 10 is provided. The running parameter 13 can, for example, comprise a length 13 to the beginning of the irregularity 12 from the unwound end of the web material 11 and / or a length to the end of the irregularity 12.In particular, an average can also be calculated from the lengths and / or both lengths can be correlated with the irregularity 12. Such a correlation is also found, for example, in . Fig. Figure 4b shows that the correlation includes the assignment of the irregularity 12 and the running parameter 13. Preferably, it can further be provided that the irregularity 12 is correlated with a time value 14, so that the time of occurrence of the irregularity 12 in the processing process can also be determined retrospectively. Thus, the correlation can be entered 104 and / or the correlation can be established by entering the irregularity 12 and the running parameter 13 into a database 40, or it can already be established beforehand and entered accordingly into the database 40. For example, in Fig. Figure 4c shows that the detection unit 20 delivers signals to a processing unit 30, which enters the irregularity 12 and the running parameter 13 into the database 40 via a communication interface 31. Preferably, the database 40 is thus part of an unwinding system 5 and can be part of an internal storage unit 41 of an unwinding device 2 or, as in Fig. 4c, is provided on an external server 42. Preferably, the monitoring method 100 further comprises a visual and / or acoustic output 105 of a warning message when the irregularity 12 is detected or the irregularity 12 is of a predefined irregularity type. The visual and / or acoustic output 105 is further Fig. Figure 4d shows a light source 62 of a display unit 60 to visually output the warning message and a loudspeaker 63 to audibly output the warning message. Further advantages arise if the method 100 includes a visualization 106 of the correlation between the irregularity 12 and the running parameter 13. Such a visualization 106 is shown in the Fig. Figure 4e illustrates this, where, for example, a graph can be displayed on a display 61 of the output unit 60, plotting a process parameter against a running parameter 13. In the illustrated embodiment, the process parameter is preferably the transparency of a printed image, although various other types of process parameters are conceivable. As shown, a parameter range 16 can be provided, which is defined by at least one parameter limit 16.1, preferably by two parameter limits 16.1, 16.2. If the process parameter exceeds one of the parameter limits 16.1 or falls below one of the parameter limits 16.2, an irregularity 12 is assumed. Several irregularities 12, 12.1 can also be correlated with several values ​​13.1, 13.2 of the running parameter 13 during visualization 106 and displayed in the graph.Thus, a probability determination 107 for a correlation of the irregularity 12 with a manufacturing process of the web material 11 and / or with the unwinding process can be carried out. For example, a further area can be defined in which the occurrence of irregularities 12, 12.1 indicates a cause in the manufacturing process of the web material 11, and the occurrence of an irregularity 12 outside this area indicates a cause in the unwinding process. Preferably, the probability determination 107 can be carried out automatically, thus further increasing the degree of automation of the procedure and thereby saving costs and improving reproducibility. In particular, a quantification procedure for determining the number of products produced from the web material 11 can be carried out using the monitoring procedure 100 and / or individual process steps of the monitoring procedure 100.

[0047] The Fig. Figures 5a to 5c show further types of irregularities. For example, they show Fig. 5a, for example, the formation of a crack in the web material 11, which can be optically detected by a detection unit 20. Thus, for example, a certain length of a crack may be tolerable, and above a certain length of crack it may be classified as an irregularity 12. Fig. Figure 5b further shows another possible irregularity 12, wherein a drive means 50 comprises drive rollers 51, which provide propulsion 11.1 of the web material 11. If, for example, a detection unit 20 determines that a preferred parameter 51.1 deviates from a target value, increased slippage at the drive rollers 51 can be detected, thus defining an irregularity 12. The slippage can, for example, comprise a difference between the actual propulsion of the web material 11 and the preferred parameter 51.1. Fig.Figure 5c further shows the opening of a foil tube, wherein the web material 11 is provided in two layers, at least in a central region, which are connected at the outer surfaces of the web material 11. To form the web material 11 into a tube shape, suction means 52 can be provided to draw in and pull apart a surface of the web material 11, so that the tube is formed from the previously flat web material 11. Due to certain events within the process, it may happen that a suction force is insufficient and the web material 11 exhibits, for example, blockages. As a result, it may not be possible for the suction means 52 to open the web material 11 at a specific point, in which case several suction attempts may be provided. Several suction attempts can also be classified as an irregularity 12 and reported to a processing unit 30.For example, the detection unit 20 can be used to measure the force of the suction means 52, whereby an increased force or a sudden drop in force can be detected as an irregularity 12 by the calculation unit 30.

[0048] The preceding explanation of the embodiment describes the present invention solely by way of examples. Naturally, individual features of the embodiment can be freely combined with one another, provided it is technically feasible, without departing from the scope of the present invention. In particular, a quantification method for determining the number of products produced from a web material can be combined with individual or all features of the embodiments, provided it is technically feasible. Reference symbol list 2 Unwinding device 5. Processing system 10 wraps 10.1 Winding sleeve 11 Railway equipment 12 Irregularity 13 running parameters 14 Time indication 16 parameter range 16.1 first parameter limit 16.2 second parameter limit 20 recording units 21 Unit of measurement 30 computing units 31 Communication interface 40 database 41 internal storage units 42 external servers 50 propulsion devices 51 Drive roller 52 Suction devices 60 output units 61 Display 62 light bulbs 63 speakers 70 changing unit 100 monitoring procedures 101 At least partial winding up 102 Recording of 12 103 Determining a correlation 104 entries in 40 105 Issuing a warning message 106 Visualizing the correlation 107 Determining a probability

Claims

[1] Monitoring method (100) for monitoring an unwinding process of an unwinding device (2), comprising the following steps: - At least partial unwinding (101) of a web material (11) from a roll (10), - Detecting (102) at least one irregularity (12) of the web material (11) and / or the unwinding process, - Determine (103) a correlation of the irregularity (12) to at least one running parameter (13) of the winding (10), wherein the running parameter (13) is determined by detecting a preferred parameter (51.1) on the web material (11), wherein the correlation of the irregularity (12) to the running parameter (13) is an assignment of a specific value of the running parameter (13) to a position of the irregularity (12) with respect to the coil (10) and / or vice versa. [2] Monitoring method (100) according to claim 1, characterized by, that the running parameter (13) is determined in particular continuously during the unwinding (101) of the web material (11) from the winding (10). [3] Monitoring method (100) according to claim 1 or 2, characterized by , that additionally a measurement of a number of revolutions (11.2) of the winding (10) is carried out. [4] Monitoring method (100) according to any one of the preceding claims, characterized by , that the monitoring procedure (100) further includes the following step: - Entering (104) the correlation of the irregularity (12) to the running parameter (13) into a database (40). [5] Monitoring method (100) according to claim 4, characterized by , that the irregularity (12) when entering the correlation into the database (40) with a time specification (14) is brought into a further correlation. [6] Monitoring method (100) according to one of claims 4 or 5, characterized bythat the database (40) is provided on an external server (42) and / or an internal storage unit (41) of the unwinding device (2). [7] Monitoring method (100) according to any one of the preceding claims, characterized by , that the monitoring procedure (100) further includes the following step: - Visual and / or audible output (105) of a warning message when the irregularity (12) is detected or the irregularity (12) is of a predefined irregularity type. [8] Monitoring method (100) according to any one of the preceding claims, characterized by , that the monitoring procedure (100) further includes the following step: - Visualizing (106) the correlation of the irregularity (12) to the running parameter (13). [9] Monitoring method (100) according to any one of the preceding claims, characterized by , that the monitoring procedure (100) further includes the following step: - Determine (107) a probability of a cause of the irregularity (12) in a manufacturing process of the web material (11) and / or in the unwinding process. [10] Monitoring method (100) according to any one of the preceding claims, characterized by , that the irregularity (12) includes a process parameter which lies outside a parameter range (16). [11] Monitoring method (100) according to any one of the preceding claims, characterized by , that on the basis of the running parameter (13) a number of products produced from the web material (11) is determined. [12] Unwinding device (2) for carrying out an unwinding process of a web material (11) from a coil (10), wherein the unwinding process is monitored by a monitoring method (100) according to one of the preceding claims, comprising a winding holder (70) on which the winding (10) can be stored during the unwinding process, a propulsion means (50) by which a propulsion (11.1) of the railway material (11) can be generated, and a detection unit (20) by which at least one irregularity (12) of the web material (11) and / or of the unwinding process can be detected, wherein the detection unit (20) is in communication connection with a computing unit (30), wherein a correlation of the irregularity (12) to at least one running parameter (13) of the winding (10) can be determined by the computing unit (30), wherein the computing unit (30) is in communication connection with a measuring unit (21) for detecting a preferred parameter (51.1) on the web material (11). [13] Unwinding device (2) according to claim 12, characterized by , that the measuring unit (21) is additionally designed to measure a number of revolutions (11.2) of the winding (10). [14] Unwinding device (2) according to one of claims 12 or 13, characterized by, that the calculation unit (30) makes it possible to calculate the running parameter (13). [15] Unwinding device (2) according to any one of claims 12 to 14, characterized by , that the computing unit (30) has a communication interface (31) for data communication with a database (40), so that the correlation of the irregularity (12) to the running parameter (13) can be entered into the database (40) via the communication interface (31). [16] Unwinding device (2) according to any one of claims 12 to 15, characterized by , that the computing unit (30) is in communication connection with an output unit (60) and is designed to issue a visual and / or acoustic warning message via the output unit (60) when the irregularity (12) is detected or the irregularity (12) is of a predefined irregularity type. [17] Unwinding system (5) for carrying out an unwinding process of a web material (11) from a coil (10), wherein the unwinding process is monitored by a monitoring method (100) according to one of claims 1 to 11, comprising an unwinding device (2), in particular according to one of claims 12 to 16, with a winding holder (70) on which the winding (10) can be stored during the unwinding process, a propulsion means (50) by which a propulsion (11.1) of the railway material (11) can be generated, and a detection unit (20) by which at least one irregularity (12) of the web material (11) and / or of the unwinding process can be detected, wherein the detection unit (20) is in communication connection with a computing unit (30), wherein a correlation of the irregularity (12) to at least one running parameter (13) of the winding (10) can be determined by the computing unit (30), wherein the computing unit (30) is in communication connection with a measuring unit (21) for detecting a preferred parameter (51.1) on the web material (11). [18] Unwinding system (5) according to claim 17, characterized by , that an external server (42) with a database (40) is provided, which is in communication connection with the computing unit (30) via a communication interface (31), so that the correlation of the irregularity (12) to the running parameter (13) can be entered into the database (40).

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