SYSTEM FOR MONITORING GLASS CONTAINERS, PRODUCTION PLANT AND PROCESS

Description

[0001] The invention relates to a system for monitoring glass containers produced by an IS machine and conveyed into a cooling oven, comprising a sensor device and a control device. The invention further relates to a production plant with an IS machine and a method for operating a production plant with an IS machine.

[0002] IS machines for the production of glass containers have been known in the art for decades. The function of an IS machine is typically as follows: Glass is melted in a tank. This is conveyed through a trough (feeder channel). At the end of the feeder channel is a glass outlet (spout). In the spout, the glass is homogenized by means of an agitator or a rotating tube. The tube also serves to meter the glass flow. A plunger forces the glass out of the spout. As the plunger retracts, a portioned piece of glass (drop) is cut off by a shear.

[0003] A droplet distributor feeds the glass slabs to the individual sections via metal troughs. Container forming in an IS machine is a two-stage process. In the first stage, a preform is pressed or blown. In the second stage, the preform is blown into the final container mold. During both process steps, the preform and the container are continuously cooled. Once thermal stability is achieved, the container is removed from the mold and placed on a settling plate. There, it continues to be cooled to prevent reheating and further deformation.

[0004] From the IS machine's unloading plates, the containers are transported to an annealing oven. First, a pusher moves the containers from the unloading plate onto the conveyor belt. A light barrier and an ejector are installed on the conveyor belt. The ejector removes containers, lubrication containers, or other defective containers from the transport after the start of a section. Next, the conveyor belt passes through a tempering tunnel where the containers receive a coating that reduces their scratch resistance. The containers are then typically guided to a deflection point. This changes the transport direction by 90° and reduces the spacing between the containers. A cross conveyor in front of the annealing oven entrance transports the containers for insertion into the oven. A pusher then inserts the containers into the annealing oven in rows, across the oven's width.The containers are transported through the cooling oven on a cooling oven conveyor belt.

[0005] Once the glass containers are formed, they are removed from the molds by a removal device, typically to a settling plate where they are cooled and from where they are pushed onto the conveyor belt. A conventional removal device, for example, is designed for use with a double-drop molding machine and comprises two removal grippers, a gripper carrier, and a mechanism that moves the carrier to switch the grippers between a receiving position, where they pick up formed glass articles from the machine's molds, and a settling position, where they convey the glass articles, for example, to a cooling station.

[0006] When using such a removal device, the required distance between the removal grippers is determined by the distance between the finished molds. Thus, without further measures, the distance between the finished molds would also determine the distance between the glass containers on the settling plate. Conventional ejection mechanisms that push the glass containers from the settling plate onto a conveyor belt can modify the distance between the glass containers on the conveyor belt by adjusting the distance of the ejection fingers relative to the distance on the settling plate. However, the extent to which this is possible is severely limited by the size and spacing of the glass containers and the need to position the fingers between them. This limitation is even greater for a three- or four-drop machine than for a two-drop machine.Even if attempts are made to change the distance, at least one of the ejection fingers inevitably moves relatively quickly when it touches the corresponding glass container, creating a risk of damaging the glass container.

[0007] With the increasing use of multi-drop machines and efforts to increase the operating speed of IS machines, it is also necessary to increase conveying speeds. However, it is also important to adjust the conveying speed in a way that considers economic aspects and avoids problems with instability of the glass containers on the conveyor belt at higher speeds. For this reason, the aim is generally to achieve a spacing between the glass containers on the conveyor belt that is smaller than the spacing between the finished molds. A smaller spacing between the glass containers on the conveyor belt allows for a lower conveyor speed, which promotes stable and trouble-free transport of the glass containers.

[0008] DE 197 20 664 A1 describes a device for manufacturing glass bodies. The device includes a transfer unit for moving hot glass bodies from the production area to a cooling area. Furthermore, a test unit for optically inspecting the hot glass bodies for defects is provided. The test unit is located within the transfer unit, allowing the hot glass blanks to be tested before final production after cooling. This saves raw materials, energy, and time compared to conventional manufacturing processes and equipment.

[0009] DE 38 52 864 T2 describes a device for transporting and inspecting containers, comprising a cooling oven for cooling the containers, a feed conveying device having a section located near the cooling oven for transporting the containers from a source of containers to the cooling oven, an inspection device for inspecting at least one of the containers, and a stacking device located on the side of the cooling oven opposite the section of the conveying device for transferring containers from the section of the conveying device to the cooling oven. The stacking device has a reciprocating push rod for contacting the containers, and means are provided for selectively diverting containers supplied to the feed conveying device to the inspection device before these containers are pushed into the cooling oven.as well as means for returning such diverted containers to the feed conveying device or to the cooling oven, which have been determined by the control device to be usable.

[0010] DE 10 2004 007 507 A1 describes a device for moving glassware, particularly hollow glassware. The glassware is located on a transversely moving belt (transverse belt) and is moved from there onto a longitudinally moving belt (longitudinal belt). For this purpose, the device has a moving element consisting of a slide with recesses in which the glassware rests, and a support element to which the slide is attached. The slide performs cycles, moving from a neutral position to a final position via a non-linear movement (moving motion), thereby moving the glassware. The device further comprises a moving element that moves the slide and a control element that controls the movements of the moving element.The moving part can perform at least three independent rotational movements, whereby the translational movement is achieved through the combination of these rotational movements.

[0011] FR 2 820 730 A1 describes a line feeder for bottles in individual guides with a push bar that moves synchronously with the feed. The feeder has a bar attached to a pusher that engages with bottles on a feed conveyor and transfers a row of bottles obliquely to the conveying direction onto a conveyor running transversely to it. The speed component of the bar in the direction of the feed conveyor is synchronized with the speed of the intermediate conveyor, depending on the bar's feed rate.

[0012] This US patent 4,801,319 A1 relates to an apparatus and an associated method for the automated random inspection of containers, and in particular glass containers, wherein the inspection takes place before the container enters the hot inlet of an annealing furnace. The apparatus and the associated method comprise a main conveyor belt that positions an array of containers next to an annealing furnace, and a stacking device with a reciprocating push bar that inserts the containers—with the exception of certain containers designated for inspection—into the annealing furnace in rows.

[0013] JP 2003 083718 A describes a visual inspection system for the high-speed detection of shape and position deviations in numerous objects transported on a conveyor belt. A surface camera and several side cameras monitor the products to detect deviations in external shape and position. If a deviation is detected, a warning signal is triggered and an ejection system is activated.

[0014] The object of the invention is to provide solutions related to IS machines in order to increase the working speed, reduce rejects and improve the possibilities for monitoring glass container production.

[0015] This problem is solved by the subject matter of the independent patent claims. Preferred embodiments of the invention are described in the dependent claims.

[0016] According to the invention, a system for monitoring glass containers produced by means of an IS machine and conveyed into a cooling oven is provided, comprising a sensor device for capturing movement information of the glass containers and a control device which is configured to provide position parameters of the glass containers based on the movement information and / or to transmit them to a feeder device provided for conveying the glass containers to the cooling oven for controlling movements of the feeder device.

[0017] In other words, a monitoring system is proposed to record the movement and position (motion information) of hot glass containers as they move towards a cooling facility (cooling oven) – typically on a conveyor belt and possibly a subsequent cross conveyor – and to generate position parameters from this data. Specifically, the monitoring system can collect data on the movement of the glass containers and process it as position parameters. These position parameters can be provided, for example, to a machine operator and, alternatively or additionally, to a loading device to adapt its operation and control to the actual conditions.

[0018] The invention advantageously provides a system for monitoring the insertion process of hot glass containers into the annealing furnace, for example, from a transverse conveyor onto an annealing furnace conveyor running through the furnace. The system can be used, in particular, from the point where the glass containers are threaded into a feeder comb of the insertion device until they enter the annealing furnace. Thanks to the system, rejects can be reduced and / or the conveying speed increased, for example, because a machine operator can better locate sources of error. The system also provides the possibility of collecting data for process monitoring. Furthermore, the system enables the machine operator or machine manager to be supported in carrying out changeovers by means of motion information or position parameters.

[0019] The insertion device preferably includes an insertion comb. The insertion comb is designed for threading several, for example, three, four, five, six, preferably ten or more, glass containers, especially while still hot. Preferably, up to 70 still-hot glass containers can be inserted using the insertion comb. The insertion device or the insertion comb expediently comprises a heat-resistant material for contact with the still-hot glass containers. The threaded glass containers can be conveyed or pushed along a path of movement by means of the insertion comb, e.g., horizontally along a surface, especially while the glass containers are upright. The insertion device can move the insertion comb in a controlled manner. The insertion device is particularly designed for intermittent operation, especially in sync with a conveyor belt or cross conveyor.The path of movement is, in particular, a curved path that preferably runs partially in the conveying direction of the cross belt or the machine belt. The feed device can have at least one servo motor or several servo motors designed to move the feed comb.

[0020] A conveyor belt or cross conveyor as defined in the present disclosure preferably comprises an endless belt for the particularly straight conveying of glass containers. The endless belt runs, for example, in one direction on the top side and in the opposite direction on the bottom side. The belt can be oriented horizontally, ascending or descending, in sections or completely. The belt expediently comprises a heat-resistant material for supporting the hot glass containers.

[0021] The sensor device can capture and provide motion information in data format. According to the invention, the sensor device is a camera, such as a webcam, which can, for example, provide image or video material. Typically, the sensor device must be protected from heat from the glass containers. Therefore, a housing and / or cooling system is preferably provided as such heat protection.

[0022] In particular, the control device is connected to the sensor device and / or can receive motion information from the sensor device. Preferably, the control device includes a computer. The control device can regularly use or process the motion information to generate the position parameters. Ultimately, the control device preferably serves to process data from the sensor device in order to retrieve it or forward it for control / regulation, e.g., to the insertion device. The control device can execute software or a computer program. The control device can be integrated with the sensor device and / or provided in an IS machine or production plant.

[0023] Position parameters are understood to be, in particular, data relating to the glass containers. Advantageously, these position parameters are derived from motion information. For example, the motion information is evaluated or processed to generate position parameters. Preferably, image processing of photographs is used to determine the distance between two specific glass containers.

[0024] When position parameters are transmitted to the insertion device, it is possible for the insertion device to be controlled by them. For example, the insertion device can implement a motion correction to more reliably thread the glass containers into the machine or to convey or push them to the cooling oven. In this respect, it is preferred that the control device generates and transmits suitable motion data or motion curves for the insertion device under the general term "position parameters." However, the insertion device itself can also be configured to generate motion curves from position parameters.

[0025] According to the invention, the sensor device includes a camera for providing image information about the glass containers. The motion information can include or be formed by the image information. The camera is used in particular for detecting the glass containers. For example, an image sensor or CCD sensor and optics are provided to optically detect the glass containers and / or to generate the image information. In particular, the camera is a digital camera. The camera can be equipped with lighting for the glass containers. Several cameras can also be provided, for example, in a number corresponding to the number of glass containers that are to be conveyed or pushed simultaneously to the cooling oven by means of a loading device.

[0026] The camera (or cameras) is (or are) preferably arranged in a protective housing of the sensor device. Preferably, the sensor device is provided with a cooling device for cooling the sensor device. The cooling device may, particularly on the protective housing, include a cooling structure and / or a fan. The control device may be integrated together with the camera and, in particular, within the protective housing.

[0027] The control device is preferably configured to perform data processing in order to calculate the position parameters from the motion information. In particular, the control device can generate and / or calculate the position parameters from the camera-based image information, which is the motion information. Preferably, the control device is configured to store the image information and / or the position parameters.

[0028] According to the invention, the position parameters include a motion curve of a feeder comb of the feeder device. The position parameters also include a motion curve of the glass containers, from the moment the glass containers are threaded into the feeder device until they enter the annealing oven. The motion curve can be calculated, in particular, by the control device. This preferably enables error detection if glass containers are in an undesired position on their way to the annealing oven.

[0029] The position parameters can include the position of the glass containers on a conveyor belt and / or a cross conveyor. The position parameters can encompass the position of all glass containers to be detected or already detected by the insertion device. In particular, this enables error detection if glass containers are positioned in an undesired manner on the conveyor belt or cross conveyor.

[0030] The position parameters can include an offset between the insertion device and the position of the glass containers on a conveyor belt and / or a cross conveyor along the respective belt. In other words, the position parameters contain information about the extent to which there is a deviation between an insertion comb that engages the glass containers and an arrangement of the glass containers that corresponds to the insertion comb and its path of movement. Knowing this offset allows for the detection and correction of the insertion device, thus preventing or at least reducing errors.

[0031] The position parameters can include information about the occurrence of a container loss. A container loss specifically refers to a glass container that has fallen over, been misplaced, and / or been damaged. Container loss can occur in various ways, for example, due to a collision (e.g., at the insertion device), a manufacturing defect in a glass container, an unstable position, malfunctions, or other causes. In particular, the position parameters can include the location where the container loss occurred, enabling targeted intervention.

[0032] The system can have an interface for communication with the IS machine and / or the insertion device. Position parameters can be transmitted and / or made available for retrieval via this interface. The interface can be used to transmit the position parameters to the insertion device so that the device can be controlled accordingly, for example, to reduce container losses.

[0033] A production plant is further proposed comprising at least one IS machine, an annealing oven, a conveyor belt designed for conveying glass containers produced by the IS machine to the annealing oven, a feed device designed for conveying the glass containers from the conveyor belt to the annealing oven, and the system described above. In particular, the feed device is arranged in the area of ​​the transition between the conveyor belt and the annealing oven. The conveyor belt is preferably a transverse belt or a machine belt if no transverse belt is present. The transition from the conveyor belt preferably takes place onto an annealing oven belt, which transports the glass containers through the annealing oven.

[0034] In the production plant, the sensor device is preferably directed from above onto the loading device, the cooling oven, and / or the conveyor belt in order to capture the movement information of the glass containers as far as possible perpendicular to the surface on which the glass containers stand. Experience has shown that this method captures particularly reliable movement information.

[0035] Furthermore, a method for operating a production plant or the production plant described herein is proposed, wherein glass containers are manufactured by an IS machine and conveyed in a hot state by a belt to a cooling oven, wherein a feeder conveys several glass containers simultaneously from the belt to the cooling oven in a cycle, wherein a system continuously provides position parameters of the glass containers conveyed simultaneously to the cooling oven and / or transmits them to the feeder for controlling movements of the feeder.

[0036] The invention will now be explained in more detail with reference to the drawings and a preferred embodiment.

[0037] The drawings show Fig. 1 schematically shows a production plant with a system according to a preferred embodiment of the invention in a top view of a cross conveyor, a feed device, a cooling oven and the system.

[0038] In Fig. 1 A schematic representation of a production plant 1 is shown. The production plant 1 comprises an IS machine 100, a cooling oven 102, a cross conveyor 104 designed for conveying glass containers B produced with the IS machine 100 to the cooling oven 102, a feed device 110 designed for conveying the glass containers B from the cross conveyor 104 to the cooling oven 102, and a system 2 for monitoring the glass containers B.

[0039] The insertion device 110 comprises an insertion comb 112 and typically one or more servomotors. The servomotors are typically used to move or drive the insertion comb 112.

[0040] By way of example, a sliding comb 112 is shown here, designed for sliding six glass containers B. In other embodiments, not shown, the sliding comb can slide in many more glass containers or bottles (for example, 10 or more than 10 and / or up to 100 or more than 100 glass containers, preferably between 50 and 70, in particular 60 glass containers). In this example, the transverse belt 104 and a cooling furnace belt 103 of the cooling furnace 102 are aligned orthogonally to each other.

[0041] Production plant 1 is operated by the IS machine producing 100 glass containers B, which are then conveyed while hot to the cooling furnace 102 via a machine belt 105 and the subsequent cross belt 104. The diagram presented here is a highly simplified, basic arrangement, in which the cross belt 104 and the machine belt 105 are shown only as examples and not in their typical orientation relative to each other. A deflection point, to which the glass containers are conveyed, is not shown. There, they are transported perpendicular to the machine belt 105 via the cross belt 104 to the cooling furnace. At this deflection point, the glass containers are deflected by 90°.

[0042] The feeder 110 continuously conveys or pushes several glass containers B simultaneously along a path 114 from the cross conveyor 104 onto the annealing conveyor 103. For an example grouping of six glass containers B, the feeder 110 repeatedly performs the movement along the path 114 to convey or push the six glass containers B in rows to the annealing conveyor 103. The feeder 110 must repeatedly encounter the incoming glass containers B so that, according to the design of the feeder comb 112, the respective number of new glass containers B, in this case six new glass containers B, are conveyed from the cross conveyor 104 onto the annealing conveyor 103. Deviations in the timing can lead, for example, to losses due to collisions with and tipping over of glass containers B, to the detection of too few or too many glass containers B, and / or to mispositioning.undesired positioning on the cooling furnace belt 103. In doing so, the system 2 continuously provides position parameters of the glass containers B and transmits these to the insertion device 110 to control their movement, in particular to correct the movement path 114.

[0043] It is evident that the third and fourth rows of glass containers B in the conveying direction Y of the cooling furnace belt 103 are closer together than the corresponding second and third rows. In particular, the distance 7 is smaller than the distance 8, where distances 7 and 8 are measured along the direction of travel of the cooling furnace belt 103 and refer to the distance between two rows of glass containers B pushed onto the cooling furnace belt 103 by the loading device 110. This occurred because the loading device 110 reloaded the containers too quickly or too early. This has been corrected by transmitting the position parameters to the loading device 110, thereby adjusting the speed of the loading device 110, at least temporarily, so that the glass containers B are spaced as desired along the cooling furnace belt 103, i.e., in the direction Y.

[0044] Furthermore, it is apparent that the fifth row in the conveying direction Y of the cooling furnace belt 103, which is about to enter the covered cooling furnace 102 itself, is laterally offset by a distance 6 relative to the following four rows. The provided position parameters contain information about any such distance 6, e.g., as in this case, in the transverse direction X of the cooling furnace belt 103. This has been corrected in this case, for which purpose the position parameters were transmitted to the feeding device 110, thereby adjusting the movement path 114 for conveying the four subsequent rows such that the glass containers B are pushed onto the cooling furnace belt 103 against the direction X, i.e., offset by the distance 6.

[0045] System 2 includes a sensor device 10 for acquiring motion information from the glass containers B. The sensor device 10 is directed downwards towards the cooling furnace belt 103 or the cross belt 104. System 2 also includes a control device 20, which can provide or calculate position parameters of the glass containers B based on the motion information. These position parameters can be transmitted, in particular, from an interface 14 of the sensor device 10 to the insertion device 110, for example, to correct the movement path 114.

[0046] The sensor device 10 and the control device 20 are integrated into one another. The devices 10 and 20 are arranged together in a protective housing 11, which is primarily made of metal and protects them from the heat of the glass containers B. Furthermore, a cooling device 12, arranged on the protective housing 11, with a fan and, if necessary or alternatively, with cooling fins molded or attached to the protective housing 11 as cooling structures, provides thermal protection for the devices 10 and 20.

[0047] In this case, interface 14 is also arranged on or housed within the protective housing 11. Interface 14 may expediently include a plug connection and / or a radio-capable communication module.

[0048] The sensor device 10 includes a camera to capture motion information, more precisely image information, about the glass containers B in a detection field 3. The control device 20 can process the image information to calculate the position parameters.

[0049] The detection field 3 extends at least to the area in which the insertion device 110 or its insertion comb 112 can move. In particular, the detection field 3 covers a trailing part of the cross conveyor 104 and / or an initial part of the cooling furnace conveyor 103 of the cooling furnace 102.

[0050] The position parameters include the motion curve 114 of the feeder comb 112, a motion curve of individual glass containers B from threading into the feeder device 100 to entering the cooling oven 102, and a position of the glass containers B on the cooling oven belt 103. In particular, the position parameters include a distance 5 of the glass containers B transverse to the conveying direction Y of the cooling oven belt 103.

[0051] A distance of 7, 8 of the glass containers B along the conveying direction Y of the cooling furnace belt 103 is also recorded.

[0052] System 2 enables the detection of any misalignment between the insertion device 110 and the position of the glass containers B on the cross conveyor 104 along the conveyor belt 104, in order to correct the timing of the insertion device 110. To execute this correction, a control command can be transmitted to the insertion device 110, for example, to thread the glass containers B a few fractions of a second later or earlier, so that the glass containers B arrive more centrally in the insertion comb 112. System 2 can detect container losses and determine the location of these losses. In the event of container losses, System 2 can, for example, issue a warning and / or a control command within the production plant 1. Reference symbol list

[0053] 1 Production plant 2 System 3 Detection field 5 Distance 6 Offset 7 Distance 8 Distance 10 Sensor device 11 Protective housing 12 Cooling device 14 Interface 20 Control device 100 IS machine 102 Cooling oven 103 Cooling oven belt 104 Cross belt / belt 105 Machine belt 110 Feed device 112 Feeder comb 114 Movement path XR direction Y direction

Claims

1. A system (2) for monitoring glass containers that are produced by means of an IS machine (100) and are to be conveyed in an annealing furnace (102), comprising a sensor device (10) for capturing movement information of the glass containers, wherein the sensor device (10) comprises a camera for providing image information relating to the glass containers, and a control device (20), which is configured to provide position parameters of the glass containers on the basis of the movement information and to transmit them to an insertion apparatus (110) provided for conveying the glass containers to the annealing furnace (102) in order to control movements of the insertion apparatus (110), wherein the position parameters include a movement curve of a ridged inserter (112) of the insertion apparatus (110) and a movement curve of the glass containers from the glass containers being threaded into the insertion apparatus (110) through to them entering the annealing furnace (102).

2. The system (2) according to claim 1, wherein the control device (20) is designed to carry out data processing in order to calculate the position parameters from the image information.

3. The system (2) according to any one of the preceding claims, wherein the position parameters include: a position of the glass containers on a belt (104) which transports the glass containers perpendicularly to an annealing furnace belt (103) passing into the annealing furnace (102).

4. The system (2) according to any one of the preceding claims, wherein the position parameters include an offset between the insertion apparatus (110) and a position of the glass containers on the belt (104) which transports the glass containers perpendicularly to an annealing furnace belt (103) passing into the annealing furnace (102).

5. The system (2) according to any one of the preceding claims, wherein the position parameters include the occurrence of the loss of a container, wherein the loss of a container relates to a glass container that has fallen over and / or has been incorrectly inserted and / or has been damaged.

6. The system (2) according to the preceding claim, wherein the position parameters include the location of the occurrence of the loss of a container.

7. The system (2) according to any one of the preceding claims, comprising an interface (14) for communication with the IS machine (100) and / or with the insertion apparatus (110).

8. A production facility (1) comprising at least one IS machine (100), an annealing furnace (102), a belt (104) designed to convey glass containers produced by the IS machine (100) to the annealing furnace (102), an insertion apparatus (110) designed to convey the glass containers from the belt (104) to the annealing furnace (102), and a system (2) according to any one of the preceding claims.