Method for diagnosing a malfunction in the operation of a packaging machine

Abstract

A method for diagnosing a malfunction in the operation of a packaging machine (1) comprising a display device (19). The method comprises displaying a localization view (33) by the display device (19), wherein the localization view (33) requires a first localization input (34) from a user, and wherein the first localization input (34) localizes a fault location.The method further comprises compiling a comparison view (37) based on the first localization input (34) of the user, wherein the comparison view (37) comprises one or more representations (38) each of a packaging (21) or packaging component that can be processed by the packaging machine (1) and has a defect, and displaying the comparison view (37) by the display device (19), wherein the comparison view (37) requires a comparison selection (39) by the user, and wherein the comparison selection (39) indicates one of the one or more representations (38). The method further comprises displaying at least one fault rectification suggestion (40) based on the comparison selection (39) by the display device (19).

Description

[0001] The invention relates to methods for diagnosing malfunctions in the operation of packaging machines.

[0002] It is known to monitor the operation of packaging machines using various sensors or similar systems and to detect operational malfunctions. For example, DE 10 2019 206 389 A1 describes a method by which a tool misalignment can be detected based on the evaluation of various sensor signals.

[0003] However, some malfunctions in packaging machines manifest themselves through phenomena that cannot be detected at all or sufficiently by sensors. For example, packaging cavities formed by thermoforming packaging machines can be tested for leaks after forming by pressure testing. However, such leak detection alone may not be sufficient to efficiently identify the cause.

[0004] It is an object of the invention to provide an improved method for diagnosing malfunctions in the operation of packaging machines. This object is achieved by a method having the features of claim 1.

[0005] A method for diagnosing a malfunction in the operation of a packaging machine comprising a display device is disclosed. The method comprises displaying a localization view by the display device, wherein the localization view requires a first localization input from a user, and wherein the first localization input locates a defect location, and assembling a comparison view based on the first localization input from the user, wherein the comparison view comprises one or more representations, each of a package processable by the packaging machine having a defect. The method further comprises displaying the comparison view by the display device, wherein the comparison view requires a comparison selection from the user, and wherein the comparison selection indicates one of the one or more representations.Furthermore, the method comprises displaying at least one troubleshooting suggestion based on the comparison selection by the display device.

[0006] A malfunction can be considered to be circumstances that result in a packaging machine not producing optimal results. This can include circumstances that require the immediate interruption of operation of the packaging machine. However, circumstances that simply lead to a suboptimal result that could be improved by rectifying the malfunction can also be considered a malfunction. For example, a malfunction could result in packaging that is still suitable for further processing and / or saleable, but which could still be optimized by rectifying the malfunction. Accordingly, suggestions for rectifying malfunctions can be understood to mean measures that can restart the packaging machine's operation after an interruption in operation caused by a malfunction and / or can improve and / or optimize the operation and / or the work results of the packaging machine.

[0007] By taking into account the initial location input and the user's comparison selection, the cause of a fault can be determined more precisely. In the previously mentioned example of detecting a leak, the user can, for example, use the initial location input to specify the location of a crack in the formed packaging cavity, e.g. using a graphical representation of the packaging that can be processed by the packaging machine. Based on the initial location input, the comparison view can be compiled, which can, for example, include graphical representations of different crack shapes. The user can then use the comparison selection to specify the graphical representation of a crack shape that most closely matches the crack shape on the defective packaging cavity. Based on the location and shape of the crack, the cause of the fault, e.g.unsuitable mold pressure, unsuitable mold temperature or damage to the mold tool, can be precisely determined, or at least more precisely defined.

[0008] The inputs described above and below can be provided in different ways. For example, it is conceivable that the display device comprises one or more input elements, each of which can be configured to receive inputs from a user. Input elements can be, for example, buttons, levers, keys, buttons, touchscreens, cameras or microphones, or various combinations of the above. The input elements can be configured to receive user inputs in different ways, for example by mechanical actuation by the user, detecting a touch by the user, detecting a sound generated by a user, e.g. a voice command, or by detecting a gesture performed by the user.

[0009] Packaging machines can be considered devices and systems configured to produce packaging and / or packaging components. This can include, in particular, packaging machines or systems, including all their stations, such as the forming station, leak detection station, sealing station, and / or cutting station. Additional devices and / or auxiliary devices that can perform supplementary functions, such as labeling devices, label printers, or printing devices, can also be considered part or component of a packaging machine. Accordingly, in addition to the packaging container containing the actual product and its components, other elements belonging to the packaging, such as labels and / or sleeves, can be considered packaging components.

[0010] Depending on the type of localization input required by the localization view, the localization view can be designed differently. For example, if the localization view requires localization input related to a machine component of the packaging machine, the localization view can include a localization representation of the packaging machine. A localization representation of the packaging machine can include, for example, a graphical representation of the packaging machine and / or parts thereof and / or a textual description and / or a list of textual descriptions of various machine components.

[0011] If the localization view requires a localization input related to a package that can be processed by the packaging machine, the localization view can, for example, include a localization representation of the package and / or parts and / or components of the package that can be processed by the packaging machine. A localization representation of the package that can be processed by the packaging machine can, for example, include a graphical representation of the package and / or parts thereof and / or a textual description and / or a list of textual descriptions of various parts or components of the package.

[0012] Advantageously, each of the one or more representations of a package with a defect that can be processed by the packaging machine can comprise a graphical representation of a package with a defect that can be processed by the packaging machine. Alternatively or additionally, each of the one or more representations of a package with a defect that can be processed by the packaging machine can comprise a textual description of a package with a defect that can be processed by the packaging machine.

[0013] The localization view may, for example, require that the first localization input include a user localization input related to a machine component of the packaging machine. A localization input related to a machine component of the packaging machine may, for example, be considered an indication of which machine component is experiencing a malfunction and / or defective packaging. For example, the machine component can be specified using a graphical representation of the packaging machine or by selecting it from a list.

[0014] Additionally or alternatively, the localization view may require that the first localization input comprise a user localization input relating to a package that can be processed by the packaging machine. The localization input may relate to the finished package or to preliminary stages of the finished package or components of the packaging, e.g., to a packaging tray and / or a packaging trough and / or cover film. A localization input relating to a package that can be processed by the packaging machine may, for example, be regarded as an indication of where on the package that can be processed by the packaging machine or at which defect location a defect occurs and / or what type of defect occurs. The defect location may, for example, be a packaging tray and / or a packaging trough and / or cover film and / or a sealing seam and / or a trough wall and / or a trough base and / or a tray wall and / or a tray base.The type of defect can be, for example, a crack and / or a crack length and / or an undesired deformation and / or an incomplete seal seam.

[0015] The method may further comprise displaying a second localization view by the display device, wherein the second localization view may require a second localization input from the user, and wherein the second localization input may localize a fault location. A second localization view may, for example, make it possible to distribute a localization input related to a machine component of the packaging machine and a localization input related to a package that can be processed by the packaging machine into separate localization views. For example, the first localization input may be taken into account when compiling the second localization view. The method may comprise compiling the second localization view based on the first localization input.In embodiments where a first and a second localization input are required, the method may include assembling the comparison view based on the first and / or second localization input.

[0016] The second localization view may require that the second localization input include a user localization input related to a machine component of the packaging machine and / or to a package that can be processed by the packaging machine. With regard to the user localization input related to a machine component of the packaging machine and to a package that can be processed by the packaging machine, the above explanations with respect to the first localization input apply analogously.

[0017] The method may further comprise detecting one or more actual values ​​of one or more operating parameters of the packaging machine. For example, one or more pressures, such as a forming pressure and / or an evacuation pressure and / or a gassing pressure, may be considered operating parameters. Alternatively or additionally, one or more temperatures may be considered operating parameters, such as a forming temperature and / or a sealing temperature. The actual value of the operating parameter may be detected based on the first and / or second localization input and / or based on the comparison selection. Alternatively or additionally, a selection of which operating parameter is detected may be made based on the first and / or second localization input and / or based on the comparison selection.

[0018] It may be particularly advantageous if the display of at least one troubleshooting suggestion and / or the compilation of the first or second localization view and / or the compilation of the comparison view is carried out based on the recorded actual value of the operating parameter.

[0019] Advantageously, displaying the at least one troubleshooting suggestion can include displaying the actual value of the operating parameter. Displaying the actual value as part of displaying the troubleshooting suggestion can be based on and / or dependent on the first and / or second localization input and / or based on and / or dependent on the comparison selection.

[0020] It may be advantageous if the display of at least one troubleshooting suggestion includes displaying a suggested change to the operating parameter. For example, the suggested change may include increasing or decreasing the operating parameter and / or a machine setting that may influence the operating parameter. For example, displaying a suggested troubleshooting suggestion may include displaying a mold temperature as the actual value of an operating parameter and increasing the heating power of a heating device of a molding tool as a suggested change to a machine setting.

[0021] The application also relates to a packaging machine configured to carry out a method according to one of the preceding claims. The packaging machine comprises a display device. The packaging machine may further comprise one or more input elements. For example, the packaging machine, in particular the display device, may comprise a touch sensor, so that the display device may be designed as a touch-sensitive display.

[0022] The packaging machine may further comprise a processing unit. The processing unit may be connected to the display device. The processing unit may be configured to interact with the display device such that the various views explained above are displayed. Furthermore, the processing unit may be configured to compile the various views and / or suggestions based on the various inputs and / or selections, if applicable. In addition, the processing unit may be configured to detect the one or more operating parameters and / or receive signals representing operating parameters detected by other components of the packaging machine.Furthermore, the processing unit can be configured to change machine settings and / or generate signals that cause other components of the packaging machine to change machine settings, for example, based on a user selection input that may indicate a selection of a suggested troubleshooting option. The processing unit can comprise, for example, a computer. The processing unit can be integrated into a control unit of the packaging machine.

[0023] The invention relates to a method for diagnosing a malfunction in the operation of a packaging machine of the type described above. An advantageous embodiment is explained in more detail below by way of example with reference to drawings. Fig. 1 shows a schematic side view of a packaging machine. Fig. 2 shows a schematic view of a display device of the packaging machine from Fig. 1, which shows a first localization view. Fig. 3 shows a schematic view of a display device of the packaging machine from Fig. 1, which displays a second localization view. Fig. 4 shows a schematic view of a display device of the packaging machine from Fig. 1, which shows a comparison view. Fig. Figure 5 shows a schematic view of a display device of the packaging machine from Fig. 1, which indicates a suggested troubleshooting option.

[0024] Fig. Figure 1 shows a schematic view of a packaging machine 1, which, as in the present embodiment, may be a thermoforming packaging machine. The packaging machine 1 may have a forming station 2, a sealing station 3, a cross-cutting device 4, and a longitudinal cutting device 5. These may be arranged in the named order in a working direction R on a machine frame 6. Furthermore, a leak detection station 17 may be arranged downstream of the forming station 2.

[0025] On the input side, a feed roller 7 can be provided on the machine frame 6, from which a first packaging film 8 can be pulled off. In the area of ​​the sealing station 3, a film storage device 9 can be provided, from which a second packaging film 10 can be pulled off as a lidding film. On the output side, a removal device 13, e.g. in the form of a conveyor belt, can be provided on the packaging machine 1, with which finished, separated packages 21 can be transported away. Furthermore, the packaging machine 1 can have a feed device (not shown) which can grip the first packaging film 8 and transport it further in the working direction R in cycles, preferably in a main work cycle. The feed device can be implemented, for example, by laterally arranged transport chains, preferably clamp chains.

[0026] As shown in the illustrated embodiment, the forming station 2 can be designed as a deep-drawing station. In this station, one or more packaging cavities 14 can be formed into the first packaging film 8 by deep-drawing. For this purpose, the forming station 2 can comprise a forming tool 11.

[0027] The molding tool 11 can have a heating device 12. The heating device 12 can be arranged, in particular, within the molding tool 11. The heating device can have a heating plate 12a. The heating device 12, in particular the heating plate 12a, can be configured to heat the first packaging film 8. This allows for better plastic deformability of the first packaging film 8.

[0028] The forming station 2 can be designed such that several packaging cavities 14 can be formed next to one another in a direction perpendicular to the working direction R. An insertion section 15 can be provided in the working direction R behind the forming station 2, in particular behind the leak detection station 17. There, the packaging cavities 14 formed in the first packaging film 8 can be filled with product 16.

[0029] The sealing station 3 can have a closable chamber in which an atmosphere in the packaging cavities 14 can be replaced before sealing, for example by gas purging with a replacement gas or with a replacement gas mixture.

[0030] The cross-cutting device 4 can be designed as a punch, which can be configured to cut the first packaging film 8 and the second packaging film 10 in a direction transverse to the working direction R between adjacent packaging cavities 14. The cross-cutting device 4 can be configured such that the first packaging film 8 is not divided across its entire width, but rather remains uncut at least in one edge region. This can enable controlled further transport by the feed device.

[0031] The longitudinal cutting device 5 can, as in the illustrated embodiment, be designed as a rotating circular blade arrangement with which the first packaging film 8 and the second packaging film 10 can be severed between adjacent packaging troughs 14 and at the lateral edge of the first packaging film 8, whereby individual packages 21 can be present behind the longitudinal cutting device 5.

[0032] The packaging machine 1 may further include a control unit 18. It may be configured to control and / or monitor the processes taking place in the packaging machine 1. Furthermore, a display device 19 may be provided, preferably with input elements 20, and configured to visualize or influence process sequences in the packaging machine 1 for or by an operator.

[0033] The general operation of the packaging machine 1 can be briefly described below.

[0034] The first packaging film 8 can be pulled off the feed roll 7 and transported by the feed device into the forming station 2. In the forming station 2, one or more packaging troughs 14 can be formed in the first packaging film 8 by deep drawing. The first packaging film 8 can first be heated, preferably by a heating device 12. The deep drawing of the trough 14 can be assisted by introducing compressed air into the forming tool 11. The packaging troughs 14, together with the surrounding area of ​​the first film 8, can be transported step by step to the leak detection station 17 in a main work cycle. There they can be checked for leaks that may have occurred, for example, during forming. The packaging troughs 14 can then be transported to the insertion section 15, where they can be filled with product 16.

[0035] The filled packaging cavities 14, together with the surrounding area of ​​the first packaging film 8, can then be transported further by the feed device to the sealing station 3. The second packaging film 10 can be sealed to the first packaging film 8 as a lidding film in the sealing station 3. The second packaging film 10 can then be transported further with the feed movement of the first packaging film 8. In this process, the second packaging film 10 can be removed from the film storage 9. Sealed packages 21 can be created by sealing the lidding film 10 to the packaging cavities 14.

[0036] In the cutting devices 4, 5, the packages 21 can be separated by severing the packaging films 8, 10 in the transverse and longitudinal directions, respectively. Instead of the cutting devices 4, 5, a complete cutting device (not shown) can also be used for separation, which can separate the packages 21 in a single step.

[0037] In Fig. 2, the display device 19 is shown schematically. As in Fig. 2, the display device 19 may comprise a display 30. Furthermore, the display device may comprise the input elements 20. As shown in Fig. 2, the input elements 20 can be provided in the form of buttons 31. Alternatively or additionally, an input element 20 can be provided in the form of a touch-sensitive display or touchscreen 32. In Fig. 2, the display device 19 displays a localization view 33. The localization view 33 may require a first localization input 34 from a user.

[0038] The first localization input 34 can localize a fault location. For example, the first localization input 34, as shown in Fig. 2, a user localization input related to a machine component of the packaging machine 1. As in the present example, the first localization input 34 can be related to the leak detection station 17. This allows the fault location to be localized relative to the leak detection station 17. For example, the first localization input 34 can indicate that a fault, e.g., a faulty packaging tray 14, occurs upstream of the leak detection station 17.

[0039] Based on the first localization input 34, a second localization view 35 can be compiled. In Fig. 3 again shows a schematic view of the display device 19. In Fig. 3, the display device 19 shows the second localization view 35. The second localization view 35 may require a second localization input 36 from a user. The second localization input 36 may localize and / or further narrow down the defect location. For example, the second localization input 36 may include a user localization input related to a packaging 21 or packaging component that can be processed by the packaging machine 1. As in the present example, the second localization input 36 may be related to the packaging trough 14. As a result, the defect location can be localized relative to the packaging trough 14. For example, the second localization input 36 may indicate that a defect occurs at a transition between the trough floor and the trough wall. This may, as in Fig. 3, by touching the touchscreen at the point where the defect location is located in a displayed graphic representation of the packaging 21 or packaging component.

[0040] Based on the first localization input 34 and / or the second localization input 36, a comparison view 37 can be compiled. In Fig. 4 again shows a schematic view of the display device 19. In Fig. 4, the display device 19 shows the comparison view 37. The comparison view 37 can contain one or more (in Fig. 4, two representations 38 are shown, each of which comprises a packaging 21 and / or packaging component that can be processed by the packaging machine 1 and has a defect. As in the present exemplary embodiment, the representations 38 can each comprise a graphical representation of a packaging 21 and / or packaging component that can be processed by the packaging machine 1 and has a defect. The comparison view 37 can require a comparison selection 39 from the user. The user can compare the various representations 38 with the defective packaging 21 and / or packaging component available to him and, through the comparison selection 39, indicate which of the representations 38 is closest to the defective packaging 21 and / or packaging component.

[0041] Based on the comparison selection 39, a troubleshooting suggestion 40 can be displayed. Fig. 5 again shows a schematic view of the display device 19. In Fig. 5, the display device 19 displays the troubleshooting suggestion 40. As shown in the present embodiment, the display of the troubleshooting suggestion 40 may include displaying a change suggestion 41 of an operating parameter. In Fig. 5 shows a mold temperature as an example of an operating parameter. The amendment 41 can, as in Fig. 5 also shown as an example, include a graphic that signals to a user that the mold temperature should be increased. As shown in Fig.5, the display of the troubleshooting suggestion 40 may additionally include displaying an actual value 42 of the operating parameter. Accordingly, the method may include detecting the actual value 42 of the operating parameter, in the present embodiment, the mold temperature. It may be advantageous if the detected actual value 42 is taken into account when compiling the troubleshooting suggestion 41.

Claims

[1] A method for diagnosing a malfunction in the operation of a packaging machine (1) comprising a display device (19), the method comprising: Displaying a localization view (33) by the display device (19), wherein the localization view (33) requires a first localization input (34) from a user, and wherein the first localization input (34) locates a fault location, Compiling a comparison view (37) based on the first localization input (34) of the user, wherein the comparison view (37) comprises one or more representations (38) of a packaging (21) or packaging component that can be processed by the packaging machine (1) and has a defect, Displaying the comparison view (37) by the display device (19), wherein the comparison view (37) requires a comparison selection (39) of the user, and wherein the comparison selection (39) indicates one of the one or more representations (38), Displaying at least one troubleshooting suggestion (40) based on the comparison selection (39) by the display device (19). [2] Method according to claim 1, wherein each of the one or more representations (38) comprises a graphical representation and / or a textual description of a packaging (21) or packaging component having a defect that can be processed by the packaging machine (1). [3] The method of claim 1 or 2, wherein the localization view (33) requires that the first localization input (34) comprises a user localization input related to a machine component of the packaging machine (1). [4] Method according to one of the preceding claims, wherein the localization view (33) requires that the first localization input (34) comprises a user localization input related to a packaging (21) or packaging component that can be processed by the packaging machine (1). [5] The method of any preceding claim, further comprising displaying a second localization view (35) by the display device (19), wherein the second localization view (25) requires a second localization input (36) from the user, and wherein the second localization input (36) locates a fault location. [6] The method according to claim 5, wherein the second localization view (35) requires that the second localization input (36) comprises a user localization input related to a machine component of the packaging machine (1) and / or to a packaging (21) or packaging component that can be processed by the packaging machine (1). [7] The method of claim 5 or 6, wherein the method further comprises assembling the second localization view (35) based on the first localization input (34). [8] Method according to one of the preceding claims, further comprising detecting an actual value (42) of an operating parameter of the packaging machine (1). [9] Method according to claim 8, wherein the display of the at least one troubleshooting suggestion (40) is based on the detected actual value (42) of the operating parameter. [10] Method according to claim 8 or 9, wherein the displaying of the at least one troubleshooting suggestion (40) comprises displaying the actual value (42) of the operating parameter. [11] Method according to one of claims 8 to 10, wherein the displaying of the at least one troubleshooting suggestion (40) comprises displaying a change suggestion (41) of the operating parameter. [12] Packaging machine (1) configured to carry out a method according to any one of the preceding claims.

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