METHOD AND DEVICE FOR QUALITY ASSURANCE OF A CONTAINER TREATMENT SYSTEM

Description

[0001] The invention relates to a method for quality assurance of a container treatment plant according to independent claim 1 and a corresponding device according to independent claim 7. Status the Technology

[0002] It is known in the art to monitor the operation of tank treatment systems in order to detect and rectify potential malfunctions in the system's components. This ensures that tank treatment can be carried out with consistent quality. Typically, quality assurance involves monitoring the machine parameters of the individual components of the tank treatment system. If a deviation of a machine parameter from a target value is detected, the deviation can indicate a malfunction, and the deviation can be corrected by adjusting the machine parameter.

[0003] Furthermore, for quality assurance purposes, it is known to measure a physical property of a container after treatment and compare it with a predetermined target value. If a deviation of the physical parameter from the target value is detected, a machine parameter can be adjusted accordingly.

[0004] Furthermore, EP 3 681 692 B1 discloses the ability to record the temporal profile of a control parameter and to derive any changes in the component characteristics of a component associated with that control parameter from this profile. To determine maintenance intervals or dates according to requirements, or to schedule maintenance work based on the wear rate of individual assemblies in the various forming stations, it is also possible to extrapolate the derived change in the component characteristics to estimate the future development of the component characteristics, whereby maintenance or replacement of the component in question is scheduled based on this extrapolation.

[0005] DE 10 2018 008 855 A1 discloses a method for identifying a fault-causing defective container handling device in filling and packaging plants of the food, beverage or pharmaceutical industry, which includes the steps of detecting a multitude of faults, analyzing the sequence of occurrence of the faults and determining that faults are induced by a container handling device if faults occur periodically. Technical problem to be solved

[0006] With regard to the state of the art, the technical problem to be solved by the present invention is to specify a quality assurance method for a container treatment plant by means of which comprehensive and at the same time resource-efficient monitoring of a container treatment plant can be achieved and / or any malfunction of the container treatment plant can be reliably traced. Solution

[0007] This problem is solved according to the invention by the method for quality assurance of a container treatment plant according to independent claim 1 and the corresponding device according to independent claim 7. Preferred embodiments of the invention are covered in the dependent claims.

[0008] In the inventive method for quality assurance of a tank treatment plant, wherein the tank treatment plant comprises at least two tank treatment components, a malfunction in at least one of the at least two tank treatment components is determined by means of a quality assurance device based on a periodicity with which a deviation of a parameter from a target value is detected at a first tank treatment component.

[0009] The method according to the invention allows a quality assurance device to identify a potential malfunction in the first container treatment component itself or in another container treatment component based on the periodicity with which a deviation of a parameter is detected in the first container treatment component. In particular, a potential malfunction of an upstream container treatment component can also be inferred without having to measure the malfunction in the upstream container treatment component itself. Consequently, the method according to the invention enables comprehensive and resource-efficient monitoring of the container treatment components of the container treatment system and allows a malfunction to be reliably identified based on the detected periodicity of the deviation.In particular, the method according to the invention can also be used to detect malfunctions in container treatment components that are not or cannot be monitored using metrological methods.

[0010] A container treatment component is a component of a container treatment system that is suitable for performing a treatment step on a container. Examples of container treatment components include a heating device for tempering preforms, a blow molding machine for forming the preforms into containers, a filler for filling the containers with product, a capping device for sealing the filled containers, a sterilization device for sterilizing the containers, a direct printing device for printing on the containers, or a labeling device for labeling the containers. However, it can also refer to any other container treatment component not explicitly listed here that is suitable for performing a treatment step on a container.Each of the container treatment components can comprise a variety of container treatment units, so that a variety of containers can be treated with each of the container treatment components.

[0011] The term "parameter" refers specifically to a machine parameter of a container treatment component or a physical parameter of a container. For example, the machine parameter could be the heating power or a characteristic value of a heating device, or the pre-pressure, blowing pressure, or stretching speed of a blow molding machine. However, it could also refer to any other machine parameter not explicitly mentioned here that can influence a property of the container treated by the container treatment component. The physical parameter of the container, in turn, refers to a parameter that describes a physical property of a container treated by a container treatment component.The physical parameter could be, for example, the transmittance or absorptivity of incident electromagnetic radiation, which is transmitted or absorbed by the wall and / or bottom of the container. The density of the container material, the proportion of oriented or unoriented polymer chains in a container made of plastic, the color of the container, or similar factors can also be used as physical parameters. The physical parameter could also be an injection point offset or the size of an injection point lens. The injection point lens is understood to be the center of the injection point. The examples of physical parameters listed here are to be understood as illustrative, so that the physical parameter could also be any other physical parameter not explicitly mentioned here that is suitable for inferring the quality of the container.

[0012] The setpoint is a predefined value of the parameter. If the parameter is a machine parameter, then the setpoint of the machine parameter can, for example, be selected based on a property of a preform or container being treated by the container treatment system. If the machine parameter is, for example, a heating power, then the setpoint of the heating power can be selected based on a material composition of a preform. If the parameter is a physical parameter of a container, then the setpoint of the physical parameter can be selected to obtain a container that meets a specific product requirement or exhibits a particular property.If, for example, the container is to exhibit a certain pressure resistance, then the target value of the physical parameter for pressure resistance can be a characteristic quantity (for example, the density of the container material) by which the desired pressure resistance of the container is achieved.

[0013] Periodicity means that a parameter deviation occurs with a certain regularity. This can be, for example, a temporal periodicity, where a deviation repeatedly occurs after a specific time interval, such as after 1 second, 5 seconds, or 10 seconds. However, periodicity can also mean that, for example, a deviation from a target value is detected every xth container treated by the container treatment component, or a deviation of a parameter from a target value is detected every yth treatment process, where x represents the number of containers and y the number of treatment processes performed, and both x and y are integers.

[0014] Based on a number of control interventions already performed to correct the malfunction in at least one of the at least two container handling components, the quality assurance device either modifies a machine parameter of at least one of the at least two container handling components or issues a signal indicating that a defective component of one of the at least two container handling components must be replaced to correct the malfunction. A control intervention, in this context, is defined as the modification of a machine parameter of at least one of the at least two container handling components.For example, it can be stipulated that if the number of control interventions already performed is less than or equal to a limit value, the machine parameter is changed, and if the number of control interventions performed is greater than a limit value, a signal is issued to replace a component. This allows for targeted troubleshooting of the malfunction. In particular, it not only saves the costs of unnecessary component replacements but also avoids downtime of the tank treatment system caused by such replacements.

[0015] In one embodiment, the malfunction of at least one of the at least two container treatment components can be determined based on the periodicity with which a deviation of a parameter from a target value is detected at the first container treatment component and a characteristic parameter for at least one of the at least two container treatment components. By additionally considering the characteristic parameter of at least one of the at least two container treatment components, the malfunction can be determined with higher accuracy.

[0016] In one embodiment, the characteristic parameter can be or comprise the number of container receptacles of at least one of the at least two container handling components. If the characteristic parameter is the number of container receptacles, then, in the event of a malfunction in a container receptacle or a container handling unit associated with the container receptacle, the faulty container receptacle or container handling unit can be identified based on the periodicity with which the deviation of the parameter is detected at the first container handling component.

[0017] In one embodiment, the parameter can be a machine parameter of the first container handling component or a physical parameter of a container. Both the deviation of the machine parameter and the deviation of the container's physical parameter from a target value provide a direct indicator of a production-related defect in the container and are therefore particularly suitable parameters for verifying whether a malfunction exists in a container handling component.

[0018] In one embodiment, the quality assurance device can check whether a spare part for the defective component is contained in a magazine assigned to the tank treatment system. Thus, in the event of an irreparable malfunction of a component, it can be immediately checked whether a required spare part is available or must first be procured, thereby minimizing potential downtime of the tank treatment system.

[0019] In one embodiment, if the spare part is contained in the magazine, the defective component can be replaced by the spare part using a robot assigned to the container handling system, or an operator can be signaled that the spare part is present in the magazine assigned to the container handling system and that the defective component of at least one of the at least two container handling components must be replaced, and / or, if the defective component is not contained in the magazine, the spare part can be automatically reordered by the quality assurance system, or the reordering of the defective component by the quality assurance system must be authorized by an operator.This automated process allows the quality assurance system to immediately initiate the necessary steps in the event of a defective component, thus keeping repair-related downtime as short as possible.

[0020] The container treatment system according to the invention comprises at least two container treatment components for treating containers and a quality assurance device, wherein the quality assurance device is designed to detect a malfunction in at least one of the at least two container treatment components based on a periodicity with which a deviation of a parameter on a first container treatment component is detected.

[0021] The tank treatment system according to the invention thus enables comprehensive monitoring of the tank treatment system with minimal metrological effort, thereby advantageously improving the quality assurance of the tank treatment system. In particular, malfunctions in tank treatment components that are not directly monitored or cannot be monitored by metrological means can also be detected.

[0022] The quality assurance device is designed to rectify a malfunction in at least one of the at least two tank handling components based on a number of control interventions already performed to correct the malfunction in at least one of the at least two tank handling components. This can be achieved by either changing a machine parameter of at least one of the at least two tank handling components or by issuing a signal indicating that a defective component of at least one of the at least two tank handling components must be replaced to rectify the malfunction. This allows for a targeted response to the malfunction and, in particular, saves costs associated with unnecessary component replacements or avoids downtime of the tank handling system caused by such replacements.

[0023] In one embodiment, the quality assurance device can be configured to determine the malfunction of at least one of the at least two container treatment components based on the periodicity with which a deviation of a parameter is detected at a first container treatment component and a characteristic parameter for at least one of the at least two container treatment components. By additionally considering the characteristic parameter of at least one of the at least two container treatment components, the malfunction can be determined with higher accuracy.

[0024] In one embodiment, the characteristic parameter can be or comprise the number of container receptacles of at least one of the at least two container handling components. If the characteristic parameter is the number of container receptacles, then, based on the periodicity with which the deviation of the parameter is detected at the first container handling component, the defective container receptacle or container handling unit can be identified if a malfunction occurs at a container receptacle or in a container handling unit associated with the container receptacle.

[0025] In one embodiment, the parameter can be a machine parameter of the first container handling component or a physical parameter of a container. Both the deviation of the machine parameter and the deviation of a physical parameter of the container are direct indicators of a production-related defect in the container and are therefore particularly suitable parameters for verifying whether a malfunction of a container handling component exists.

[0026] In one embodiment, the tank treatment system can include a magazine for spare parts for the at least two tank treatment components, and the quality assurance device can be configured to check whether the defective component is contained in the magazine. Providing a magazine with spare parts enables the immediate replacement of a defective component and avoids extended downtime of the tank treatment system.

[0027] In one embodiment, the container treatment system can include a robot designed to replace the defective component of at least one of the at least two container treatment components with a spare part from the magazine. The replacement process can be carried out fully automatically by the robot's automatic exchange of the defective component. This reduces downtime for repairs and also saves resources.

[0028] In one embodiment, the quality assurance system can be connected to a server and configured to automatically reorder the defective component if it is not in the magazine. This reordering can be performed either automatically by the quality assurance system or requires operator approval. Automated reordering of the spare part by the quality assurance system allows for maximum process efficiency. Furthermore, it saves resources and prevents potential errors during reordering, such as ordering the wrong component. Brief description of the characters

[0029] Figure 1: Container treatment system comprising a plurality of container treatment components and a quality assurance device according to one embodiment. Figure 2: Detail of a container treatment system comprising a plurality of container treatment components and a quality assurance device according to another embodiment. Detailed description of the characters

[0030] Figure 1Figure 1 shows a container treatment system 100 comprising four container treatment components 101, 102, 103, 104 and a quality assurance device 105 according to one embodiment. The number of four container treatment components shown in this embodiment is to be understood as exemplary and not limiting. In an alternative embodiment, any other number of container treatment components greater than 1 can also be provided. The quality assurance device 105 (for example, a computer or a control unit of the container treatment system) is configured to detect a malfunction in at least one of the container treatment components 101, 102, 103, 104 based on a periodicity with which a deviation of a parameter at a first container treatment component 101, 102, 103, 104 from a target value is detected.

[0031] A container treatment component 101, 102, 103, 104 is understood to be a component of the container treatment system which is configured to perform a treatment step on a preform or a container 106. The container treatment component 101, 102, 103, 104 can be, for example, a heating device for tempering preforms, a blow molding machine for forming preforms into containers, a device for surface treatment of containers, a sterilization device for containers, a filler for filling containers with a product, a sealing device for closing containers, a direct printing device for printing on containers, or a labeling device for labeling containers. The aforementioned configurations of the container treatment component are to be understood as examples.The container treatment component can also be any other container treatment component not explicitly mentioned here, which is suitable for performing a treatment step on a container. Basically, a container treatment component is understood to be a machine that can perform at least one treatment step on a container and, for this purpose, comprises at least one, preferably a plurality of, treatment stations of the same type. Treatment stations of the same type are understood here to mean treatment stations that are configured to perform all the same functions.

[0032] Preferably, the container treatment components can be designed as rotary machines (carousels) according to the embodiments of the invention, each comprising the described treatment stations.

[0033] The container treatment plant is designed to treat containers of all types. Preferably, these containers are bottles made of plastic or fiber-reinforced material used in the beverage industry. However, they can also be any other type of container, such as syringes, tubes, or cans made of plastic or fiber-reinforced material, as used in the food, pharmaceutical, or healthcare industries.

[0034] The parameter can be a machine parameter of a container treatment component 101, 102, 103, 104, or a physical parameter of a container 106. The machine parameter is understood to be, in particular, a machine parameter that influences a property of a preform or container 106 treated with the container treatment component 101, 102, 103, 104. If the container treatment component 101, 102, 103, 104 is, for example, designed as a blow molding machine, then the machine parameter can be a pre-pressure, a blowing pressure, or a stretching speed. The physical parameter can be, for example, a transmittance or absorptivity of incident electromagnetic radiation that is transmitted or absorbed by a wall and / or the bottom of the container.Physical parameters can also include the density of the container material, the proportion of oriented or unoriented polymer chains in a plastic container, the container's color, or similar characteristics. Alternatively, the physical parameter could be an offset injection point or the size of a sprue. However, it could also be any other physical parameter not explicitly mentioned here that is suitable for inferring the container's quality.

[0035] The setpoint is a predefined value of the parameter. If the parameter is a machine parameter, then the setpoint of the machine parameter can, for example, be selected based on a property of a preform or container being treated by the container treatment system. If the machine parameter is, for example, a heating power, then the setpoint of the heating power can be selected based on a material composition of a preform. If the parameter is a physical parameter of a container, then the physical parameter can be selected such that the container meets a specific product requirement, such as a certain pressure resistance, or exhibits a specific property.

[0036] Periodicity means that a parameter deviation occurs with a certain regularity. Periodicity can, for example, refer to temporal periodicity. A parameter deviation from a target value might occur after a specific time interval, such as 1 second, 5 seconds, or 10 seconds. However, periodicity can also mean that a parameter deviation from a target value is detected every xth time a container 106 is treated by the container treatment component 101, 102, 103, 104, or that a parameter deviation from a target value is detected every yth time a container treatment component performs a treatment step.

[0037] In the Figure 1In the embodiment shown, the four container treatment components 101, 102, 103, 104 are configured as four rotary machines 101, 102, 103, 104, wherein a plurality of container treatment stations, each with a container receptacle 107, are arranged along the circumference of each of the four rotary machines 101, 102, 103, 104. A container receptacle is understood to be a receptacle configured to receive a container or a mold for manufacturing a container. Each of the container receptacles can in turn be assigned a container treatment unit 109a, 109b, 109c, 109d (as part of the container treatment station) for carrying out a treatment step on a container 106.By equipping each of the four container treatment components 101, 102, 103, 104 with a plurality of container holders 107 and container treatment units 109a, 109b, 109c, 109d, a plurality of containers 106 can be treated with each of the container treatment components 101, 102, 103, 104. In the embodiment described here, the first container treatment component 101 comprises twelve container holders 107, the second container treatment component 102 comprises eight container holders 107, the third container treatment component 103 comprises sixteen container holders 107, and the fourth container treatment component 104 comprises four container holders 107. The number of container holders 107 and container treatment units 109a, 109b, 109c, 109d provided on or at each of the four container treatment components is to be understood as exemplary.In general, each of the container handling components 101, 102, 103, 104 can have any number of container receptacles 107 and container handling units 109a, 109b, 109c, 109d.

[0038] In the exemplary embodiment of the Figure 1The first rotary machine 101 is designed as a blow molding machine. A blow mold 108 is arranged in each of the container holders 107 of the first rotary machine 101, in which preforms can be extruded into a container 106 by means of a blow molding unit 109a. The containers produced by the first rotary machine 101 can then be transferred to the second rotary machine 102, which can be a filling device. Each container holder 107 of the second rotary machine 102 is assigned a filling unit 109b to fill the containers 106 with a product. The filled containers 106 are then transferred to the third rotary machine 103, which can be configured as a capping device.Each of the container holders 107 of the third rotary machine 103 is assigned a sealing unit 109c, by means of which the filled containers 106 can be sealed. The sealed containers 106 are then transferred to a fourth rotary machine 104, which may be a direct printing device. Each of the container holders of the fourth rotary machine 104 is assigned a direct printing unit 109d to provide the surface of the container 106 with a printed image.

[0039] In the embodiment discussed here, the fourth rotary machine 104 is also configured to determine a physical parameter or property of the container in order to check the container 106 with regard to its quality. For example, the fourth rotary machine 104 can include a camera that can inspect the surface of the container 106 for possible irregularities. The specific configuration of the four container treatment components 101, 102, 103, 104 discussed here is to be understood as exemplary. Each of the four container treatment components 101, 102, 103, 104 can also be configured as any other type of container treatment system.

[0040] Optionally, each of the container treatment components (rotary machines) 101, 102, 103, 104 can be assigned a control unit configured to control the function of that container treatment component 101, 102, 103, 104. This can be achieved, for example, by changing a machine parameter of a container treatment component. In one embodiment, the control device can, for example, control the function of each of the container treatment units 109a, 109b, 109c, 109d of the container treatment components 101, 102, 103, 104. In another embodiment, the control unit can also be configured to control the rotational speed of each of the rotary machines.

[0041] The related to Figure 1The discussed configuration of the container treatment components as rotary machines 101, 102, 103, 104 is to be understood as exemplary. Alternatively, the container treatment components can also be designed as linearly operating container treatment components. It is also possible that some of the container treatment components are designed as linearly operating machines and some of the container treatment components as rotary machines.

[0042] The quality assurance device 105 is designed to monitor the function of the container treatment system 100, to detect a malfunction in one of the container treatment components 101, 102, 103, 104, and to precisely locate the cause of the malfunction. The quality assurance device 105 is specifically designed to determine a malfunction in at least one of the container treatment components 101, 102, 103, 104 based on a periodicity with which a deviation of a parameter from a target value is detected at a first container treatment component (rotary machine) 101, 102, 103, 104. In one embodiment, the quality assurance device 105 can be configured as a computer.The quality assurance device 105 can be connected to the container handling components 101, 102, 103, 104 via a physical data line and access and evaluate a variety of different parameters of the container handling components 101, 102, 103, 104. Alternatively, the quality assurance device 105 can also be connected to the individual container handling components 101, 102, 103, 104 via a wireless data connection. As described above, the parameter can be a machine parameter of one of the container handling components or a physical parameter of a container that is measured using one of the container handling components 101, 102, 103, 104.

[0043] The quality assurance device 105 can include a storage device in which target values ​​for the numerous machine parameters of the container handling components 101, 102, 103, 104 or for the physical parameters of a container 106 are stored. In particular, the storage device can contain a large number of data records assigned to a specific type of container, so that the quality assurance device 105 can access the correct data record of reference data even when handling different containers. The storage device can also contain characteristic values ​​for each of the container handling components 101, 102, 103, 104. One characteristic value could, for example, be the number of container fixtures 107 arranged on each of the container handling components 101, 102, 103, 104.

[0044] By comparing the parameters provided by the container treatment components with the corresponding target values, the quality assurance system 105 can determine if a parameter deviates from a target value. If a deviation of a parameter of a container treatment component from a target value is detected, the quality assurance system 105 can check whether the deviation occurs repeatedly and whether the repeated occurrence of the deviation exhibits a periodicity. For example, the quality assurance system 105 can determine whether the repeatedly occurring deviation exhibits a periodicity over time, or whether a deviation occurs in a container treatment component after a certain number of containers have been treated.Based on the periodicity with which a deviation of a parameter from a target value is detected at a container handling component, the quality assurance device 105 can then determine whether a malfunction exists at one of the container handling components. In addition to the periodicity, the quality assurance device 105 can also use other parameters to determine a fault, such as the number of container grips 107 of the container handling components 101, 102, 103, 104 or the rotational speeds of the container handling components, in order to detect the malfunction with even higher precision.

[0045] In one embodiment, each container handling component may comprise any number m of container handling stations, where m is an integer and can have a different value for each component. A container handling station may include a container receiving unit and a container handling unit. If, for example, a deviation of a parameter from a target value is detected at a first container handling component by the quality assurance device, the quality assurance device may be configured to check for a predetermined period Z whether the deviation of the parameter from a target value occurs repeatedly. If repeated occurrences of the deviation are detected, the quality assurance device may determine the occurrence of the deviation of the parameter from a target value as a function of time A(t).By Fourier transforming the resulting function A(t), a frequency fA can be determined at which the deviation occurs. In one embodiment, the quality assurance device can also determine multiple frequencies fA1, fA2, ... using the Fourier transform. This is the case when the function A(t) contains at least two deviations occurring with different temporal regularities. This can be the case, for example, when a malfunction exists in at least two different container handling components, so that a characteristic frequency can be determined for each of the at least two malfunctions.

[0046] The quality assurance system can detect a malfunction in one of the container handling components based on the frequency. For this purpose, the frequency fA obtained through the Fourier transform can be compared with a rotation frequency fR = 1 / Tx, characteristic for each container handling component, where Tx represents the time a container handling component x, designed as a rotary machine, requires for one full rotation around its own axis. Alternatively, the number of container handling stations traversed before the malfunction recurs can be used. Both will be understood here as "time".If the frequency fA determined by the quality assurance system matches one of the frequencies fR characteristic of the tank handling components, then the quality assurance system can detect a malfunction of the tank handling component corresponding to that frequency fR. If more than one frequency is detected, then the presence of a problem in more than one tank handling component can also be determined.

[0047] In one embodiment, the quality assurance device for detecting a malfunction in a container treatment component can additionally use a characteristic parameter for each of the container treatment components, such as the number of container treatment stations m of a container treatment component. Furthermore, the container treatment system can be configured, based on the frequency f A and the parameters or frequency f R characteristic of the container treatment components and / or the number of container stations m, not to identify the faulty container treatment component, but rather, for example, to identify a region of the container treatment component or a specific container treatment station of a container treatment component that exhibits the malfunction.

[0048] If no malfunction of a container handling component can be detected based on the determined frequency f A (especially if the frequency f A does not correspond to any characteristic frequency f R of the container handling components or the Fourier transformations provide a continuous spectrum of frequencies and thus no dominant contributions of a characteristic frequency f A), then it may be provided that an optical or acoustic fault signal is output by the quality assurance device.

[0049] In another embodiment, for example, the quality assurance device 105 can detect a deviation of a parameter from a target value every third complete cycle of the fourth container handling component 104. The deviation could, for example, be an irregularity on the surface of a container, which was detected by the camera optionally arranged on the fourth container handling component. Based on the fact that the fourth container handling component 104 comprises four container fixtures 107 and that the parameter deviation occurs every third complete cycle of the fourth container handling component 104, the quality assurance device 105 can determine that every twelfth container 106 treated by the fourth container handling component 104 has a defect.Based on this information, the quality assurance device 105 can determine that the malfunction must be in the first container handling component 101, since only this component has 12 container holders. If the quality assurance device 105 uses further parameters of the container handling components, such as the angular velocity at which the container handling components are rotated, then the exact container holder and the blow mold 108 associated with the container holder of the first container handling component 101 that is malfunctioning can be determined.

[0050] In an alternative embodiment, for example, it may be provided that, with every half revolution of the third container handling component 103, a machine parameter characteristic of the closing process deviates from a target value. Since the third container handling component 103 comprises sixteen container receptacles, the quality control device detects that a problem occurs during the closing of every eighth container closed by the third container handling component. Based on this information, the quality control device 105 can determine that there must be a malfunction in the second container handling component, since only this component has eight container receptacles 107 and associated container handling units 109b.The quality assurance device 105 can use the rotational speed of the container handling components to trace the malfunction back to the container handling unit 109b. In the embodiment described here, for example, mechanical damage in the head region of the container caused by one of the filling units 109b could be responsible for the deviation of the parameter characteristic of the closing process for the third container handling component 103.

[0051] To rectify the malfunction in a container handling component 101, 102, 103, 104, a machine parameter can, for example, be readjusted. In the embodiment discussed above, the faulty filling unit 109b can be recentered to prevent contact with the head of the container 106. Alternatively, the faulty component can be replaced with a suitable spare part.

[0052] It is intended that, based on the number of control interventions already performed to correct a specific malfunction, a decision will be automatically made (for example, by the quality assurance device and / or a control unit of the relevant tank handling component and / or a central control unit of the tank handling system) as to whether the problem can be resolved by adjusting a machine parameter or whether a component needs to be replaced. For example, if the number of control interventions already performed is less than or equal to a certain threshold, a machine parameter will be adjusted. If the number of control interventions already performed is greater than a certain threshold, then a signal, for example, visual or audible (e.g., to an operator), will be issued indicating that a specific component needs to be replaced.The threshold value can be chosen based on the specific malfunction. For example, in the case of a first malfunction, only a small number of control interventions, such as one or two, might be initiated. In the case of a second malfunction, a higher number of control interventions, such as ten or fifteen, might be initiated before a component replacement is performed. In the case of a third malfunction, it might be the case that no adjustments are made at all and the faulty component is immediately replaced.

[0053] Figure 2 shows an excerpt 200 of which is already related to the Figure 1The discussed container treatment system 100 according to a further embodiment. In the embodiment shown here, the container treatment system 200 additionally comprises a magazine 203 and a robot 201. The robot 201 is configured to replace a defective component 108a on one of the container treatment components with a spare part 108b contained in the magazine 203.

[0054] As detailed in connection with the Figure 1 As discussed, it is intended that the quality assurance device 105 will decide, based on the number of control interventions already carried out to correct a malfunction, whether the malfunction can be corrected by adjusting a machine parameter, or whether it is necessary to replace the faulty component.

[0055] To minimize downtime of the tank treatment system 200 due to repairs in the event of a component replacement, the tank treatment system 200 can include a magazine 203 in which spare parts 108b for the various tank treatment components can be stored. The magazine can also include a computer 207 with a storage device, the storage device containing a database in which all spare parts 108b contained in the magazine 203 are listed.

[0056] In one embodiment, each of the spare parts 108b may be assigned a unique identifier, so that each component of the various container treatment components 101, 102, 10, 104 can be uniquely assigned a spare part 108b from the magazine 203. Alternatively, a database containing an overview of all the spare parts contained in the magazine 203 may be stored centrally on an external server.

[0057] If the quality assurance system 105 detects that replacing the defective component 108a is necessary to rectify the fault, it can easily check whether the defective component is contained in magazine 203 by querying the database. If the database is stored on an external server, the quality assurance system 105 can be connected to this server. If the quality assurance system 105 determines that the required spare part is contained in the magazine, it can inform an operator 205 via an interface 204 about the defective component 108a and the spare part 108b located in magazine 203. Additional information about the defective component 108a can also be provided to the operator 205.

[0058] In one embodiment, the changeover is performed fully automatically by the robot 201. Alternatively, an operator 205 can accompany the robot 201 during the component changeover. The quality assurance device 105 can provide the robot 201 with precise information about the existing defect in the container handling component and the exact storage location of the spare part 108b in the magazine 203. Based on the information provided by the quality assurance device 105, the robot 201 can replace the defective component of the container handling component fully automatically. The robot can then provide the quality assurance device 105 with information on whether the component changeover was successful or whether any problems occurred during the changeover.If the changeover was successful, the quality assurance system 105 can initiate steps so that the operation of the container handling system is automatically resumed. If the robot reports a problem during the component changeover, the quality assurance system 105 can notify an operator 205 to resolve the problem.

[0059] The robot 201 can include an arm 202 with multiple joints to enable even complex component changes. The robot can, for example, be mounted on a wheeled cart 206 and equipped with a navigation system to move through the container handling system to the individual container handling components. Additionally, the robot can include a safety system that detects people present in the container handling system and prevents potential collisions. Alternatively, rails can be installed in the container handling system, allowing the robot to move only along a path defined by the rails through the system and to the respective container handling components. For this purpose, the robot can be mounted on a cart, with the cart and the rails forming a linear drive.It is also possible to assign exactly one robot to each container handling component, which performs the replacement of spare parts for only that container handling component. Likewise, each container handling component can be assigned exactly one magazine of spare parts.

[0060] If, however, the quality assurance system 105 determines after retrieving the database that the defective component is not in stock in the magazine, then the component can be reordered fully automatically by the quality assurance system 105. To enable the reordering process to be carried out fully automatically, the quality assurance system 105 can be connected to the internet or a server. In an alternative embodiment, the ordering process can be carried out semi-automatically and must first be released by an operator 205.

Claims

1. A method for quality management of a container treatment plant (100, 200), wherein the container treatment plant (100, 200) comprises at least two container treatment components (101, 102, 103, 104), wherein by means of a quality management device (105) based on a periodicity with which at a first container treatment component (101, 102, 103, 104) a deviation of a parameter from a set value is established a malfunction of at least one of the at least two container treatment components (101, 102, 103, 104) is detected, characterized in that on the basis of the number of control actions taken on at least one of the at least two container treatment components (101, 102, 103, 104) for correcting the malfunction the quality management device (105) decides to either alter a machine parameter of the at least one of the at least two container treatment components (101,102, 103, 104) or to output a signal requesting to exchange a defective member (108a) of the one of the at least two container treatment components (101, 102,103, 104) so as to correct the malfunction on the one of the at least two container treatment components (101, 102,103, 104).

2. The method according to claim 1, wherein the malfunction of the at least one of the at least two container treatment components (101, 102,103, 104) is detected on the basis of the periodicity with which at the first container treatment component (101, 102, 103, 104) a deviation of a parameter from a set value is established and of a characteristic quantity of the at least one of the at least two container treatment components (101, 102,103,104).

3. The method according to claim 2, wherein the characteristic quantity is or comprises a number of container receptacles (107) of the at least one of the at least two container treatment components (101, 102, 103, 104).

4. The method according to any one of claims 1 to 3, wherein the parameter is a machine parameter of the first container treatment component (101, 102, 103, 104) or a physical parameter of a container (106).

5. The method according to anyone of claims 1 to 4, wherein the quality management device (105) is adapted for checking whether a replacement part for the defective member (108a) is provided in a magazine (203) associated with the container treatment plant (100, 200).

6. The method according to claim 5, wherein in case the replacement part is provided in the magazine (203), the defective member (108a) is exchanged for the replacement part (108b) by means of a robot (201) associated with the container treatment plant (100, 200) or an operator (205) is notified that the replacement part (108b) is provided in the magazine (203) associated with the container treatment plant (100, 200) and that the defective member (108a) of the at least one of the at least two container treatment components (101, 102, 103 ,104) needs to be exchanged and / or in case the defective member (108a) is not provided in the magazine (203) the replacement part (108b) is automatically reordered by the quality management device (105) or wherein the reorder of the defective member by the quality management device (104) has to be enabled by an operator (205).

7. A container treatment plant (100, 200), comprising at least two container treatment components (101, 102, 103, 104) for treating containers (106) and a quality management device (105), wherein the quality management device (105) is configured to detect a malfunction on at least one of the at least two container treatment components (101, 102, 103, 104) based on a periodicity with which at a first container treatment component (101, 102, 103, 104) a deviation of a parameter from a set value is established, characterized in that for correcting the malfunction the quality management device (105) is configured to decide on the basis of the number of control actions already taken on at least one of the at least two container treatment components (101, 102, 103, 104) to either alter a machine parameter of the at least one of the at least two container treatment components (101,102, 103, 104) or to output a signal requesting to exchange a defective member (108a) of the at least one of the at least two container treatment components (101, 102,103, 104) in order to correct the malfunction on the at least one of the at least two container treatment components (101, 102, 103, 104).

8. The container treatment plant (100, 200) according to claim 7, wherein the quality management device (105) is configured to detect the malfunction of the at least one of the at least two container treatment components (101, 102,103, 104) on the basis of the periodicity with which at the first container treatment component (101, 102, 103, 104) a deviation of a parameter from a set value is established and of a characteristic quantity of the at least one of the at least two container treatment components (101, 102,103,104).

9. The container treatment plant (100, 200) according to claim 8, wherein the characteristic quantity is or comprises a number of container receptacles of the at least one of the at least two container treatment components (101, 102, 103, 104).

10. The container treatment plant (100, 200) according to anyone of claims 7 to 9, wherein the parameter is a machine parameter of the first container treatment component (101, 102, 103, 104) or a physical parameter of a container (106).

11. The container treatment plant (100, 200) according to anyone of claims 7 to 10, wherein the container treatment plant (100, 200) comprises a magazine (203) for replacement parts (108b) for the at least two container treatment components (101, 102, 103, 104) and wherein the quality management device (105) is configured to check whether the defective member (108a) is provided in the magazine (203).

12. The container treatment plant (100, 200) according to claim 11, wherein the container treatment plant (100, 200) comprises a robot (201) which is configured to exchange the defective member (108a) of the at least one of the at least two container treatment components (101, 102, 103, 104) for a replacement part (108b) from the magazine (203).

13. The container treatment plant (100, 200) according to anyone of claims 7 to 12, wherein the quality management device (105) communicates with a server and is configured to reorder the defective member (108a) in case the member (108a) is not provided in the magazine (203), wherein the reorder of the member (108a) is carried out either automatically by the quality management device (105) or has to be enabled by an operator (205).