Modular container-processing installation

Abstract

The invention relates, inter alia, to a modular container-processing installation (58, 62, 66) comprising a main conveyor module (12, 14, 16), which is arranged for conveying containers through the modular container-processing installation (58, 62, 66), and a plurality of sub-module interfaces (52). The container-processing installation (58, 62, 66) also comprises a plurality of container-processing sub-modules (21 – 44), which can be coupled to and uncoupled from the plurality of sub-module interfaces (52). The container-processing installation (58, 62, 66) also comprises a control system which, in a self-configuring manner, is designed to automatically adapt the operation of the modular container-processing installation (58, 62, 66) depending on coupling and / or uncoupling of at least one of the plurality of container-processing sub-modules (24 – 44).

Description

[0001] DESCRIPTION

[0002] Modular container treatment plant

[0003] Technical area

[0004] The invention relates to a modular container treatment plant, a method for producing a modular container treatment plant and a method for operating a modular container treatment plant.

[0005] Technical background

[0006] In practice, the planning and commissioning of complex production plants, such as container treatment plants, which have a large number of interconnected machines, still proves to be challenging, time-consuming and inflexible.

[0007] WO 2014 / 016091 A1 describes a production plant for manufacturing and filling containers and a corresponding method. Modular processing units with stationary work modules and handling devices are provided for handling the containers between a container inlet of the processing unit and a container outlet of the processing unit, and for positioning the containers in the work module. The handling devices are configured such that the processing units can be individually exchanged, and at least two similar processing units are provided, among which the containers can be specifically distributed.

[0008] DE 10 2019 126 402 A1 discloses a device for treating containers, comprising at least one transport device for transporting the containers, a handling device for transferring containers from the transport device in a transfer area and for delivering these containers to the transport device in a delivery area, and at least one further handling device for transferring containers from the transport device in a further transfer area and for delivering these containers to the transport device in a further delivery area. At least one treatment station is assigned to each of the handling devices. The treatment stations are filling devices that at least partially fill the containers with a liquid, and these filling devices are arranged stationary with respect to the transport paths.The invention is based on the object of creating an improved container treatment plant which, in particular, enables simplified commissioning, adaptation and retrofitting.

[0009] Summary of the invention

[0010] The problem is solved by the features of the independent claims. Advantageous further developments are specified in the dependent claims and the description.

[0011] One aspect of the present disclosure relates to a modular container handling system comprising a main conveyor module, which is arranged for conveying containers through the modular container handling system, and a plurality of (e.g., standardized) sub-module interfaces. The modular container handling system further comprises a plurality of container handling sub-modules, which can be coupled to the plurality of sub-module interfaces (e.g., for commissioning) and decoupled from them (e.g., for decommissioning) (e.g., one container handling sub-module can be coupled to each sub-module interface), preferably automatically, e.g., by means of a driverless transport vehicle. The modular container handling system further comprises a (e.g.,central or distributed) control system which is self-configuring for automatically adapting an operation of the modular container treatment plant as a function of a coupling of at least one of the plurality of container treatment submodules to at least one of the plurality of submodule interfaces and / or of a decoupling of at least one of the plurality of container treatment submodules from at least one of the plurality of submodule interfaces.

[0012] Advantageously, self-configuration can significantly shorten the commissioning of the container handling system, thus bringing forward the start of production. This also applies to conversions, retrofitting, replacement, and dismantling of modules, as well as various changes in the production process, such as changing the container format, the product, or adjusting production parameters of all kinds, such as system performance. No lengthy setup processes with user assistance are necessary, as the control system can handle the setup or adjustment of the setup itself when it detects that a module is being connected or disconnected. The control system thus enables a so-called "plug and play" or "plug and produce" approach. The modules can be commissioned independently even before the first connection to one of the several submodule interfaces.During self-configuration, the control system can, for example, determine the basic configuration and specific parameters for the operation of each connected module. This self-configuration capability works synergistically with the modularity of the container treatment system, as it enables a multitude of different modular configurations without the need to develop a specific control configuration and process flow with corresponding program code for each of these configurations in advance. Thus, despite the widest variety of requirements and configurations, the modular container treatment system can always be commissioned, converted, or retrofitted in the shortest possible time, if necessary even during operation.It is possible that a test commissioning of the container treatment system or parts of it at the manufacturer's site can be omitted, thus reducing manufacturing costs. Commissioning itself requires fewer technical experts. The flexibly modular, adaptable container treatment system also enables flexible and short-term production planning, thus reducing costs and inventory expenses.

[0013] Preferably, the term "self-configuring" may refer to a control setup process that occurs without a manual setup process or with an automatic control setup process.

[0014] Preferably, the control system is further self-configuring for automatically adapting an operation of the modular container treatment plant depending on a change in production data, production specifications and / or in the event of a malfunction.

[0015] In one embodiment, the modular container processing system further comprises a plurality of main container processing modules that can be coupled to and decoupled from a plurality of (e.g., standardized) main module interfaces of the main conveyor module, preferably automatically, e.g., by means of an automated guided vehicle. The plurality of main container processing modules each comprise at least one of the plurality of submodule interfaces and a conveyor submodule that is connected or connectable to the main conveyor module for receiving the containers from the main conveyor module and for transferring the containers back to the main conveyor module (and is configured, e.g., to convey the containers to the container processing submodules coupled to the respective submodule interfaces).Preferably, the control system can further be self-configuring for automatically adapting the operation of the modular container treatment system depending on the coupling of at least one of the plurality of main container treatment modules to at least one of the plurality of main module interfaces and / or the decoupling of at least one of the plurality of main container treatment modules from at least one of the plurality of main module interfaces. Advantageously, even comparatively complex container treatment systems can thus be constructed in a modular manner, wherein the explained advantages of self-configuration can also be utilized here. Preferably, the main container treatment modules can each be equipped with functionally identical and / or functionally related container treatment submodules, so that preferably different functional units can be provided within the modular container treatment system.

[0016] In a further embodiment, the control system is configured to receive production order information for processing the containers. Preferably, the control system can further be configured to automatically adapt the operation of the modular container processing system and / or the respective connection and disconnection of the multiple container processing submodules to the multiple submodule interfaces (and preferably of the main container processing modules to the main module interfaces) depending on the received production order information. This advantageously enables flexible production, whereby, for example, very different container formats can also be processed in the container processing system. For example, it is possible for at least one connected container processing submodule to remain connected for a specific production order or for a specific batch, but unused.

[0017] Preferably, the control system can be designed to further adapt a machine power, a machine speed, a production parameter and / or a module parameter depending on the received production order information.

[0018] In one embodiment, the control system is configured to generate a movement path of the containers through the modular container treatment plant, including at least a portion of the plurality of container treatment sub-modules (and preferably the main container treatment modules), when automatically adjusting the operation, and to control a movement of the containers in accordance with the generated movement path.

[0019] In a further embodiment, the control system is configured to automatically adapt operating parameters of the main conveyor module and / or the multiple container treatment submodules (and / or the main container treatment modules) when automatically adapting the operation. In a further embodiment, the control system is configured to automatically adapt the operation and / or the respective coupling and decoupling depending on empirical data in which previous operations of the modular container treatment system and / or other container treatment systems are stored.

[0020] In one embodiment, the modular container processing system further comprises a parking station and (at least) one automated guided vehicle for transporting at least one of the multiple container processing submodules between the parking station and the multiple submodule interfaces. Alternatively or additionally, the automated guided vehicle can be designed to transport at least one of the multiple container processing main modules between the parking station and the multiple main module interfaces.

[0021] In one embodiment, the control system is designed to control, depending on received production order information, a transport of at least one of the plurality of container treatment submodules between the parking station and at least one of the plurality of submodule interfaces for coupling or uncoupling the respective container treatment submodule by means of the driverless transport vehicle.

[0022] In a further embodiment, the control system is designed to control, depending on received production order information, a transport of at least one of the plurality of container treatment main modules between the parking station and at least one of the plurality of main module interfaces for coupling or uncoupling the respective container treatment main module by means of the driverless transport vehicle.

[0023] In one embodiment, the control system is configured to generate and / or receive fault information indicating a predicted or current defect of a component and, depending on the fault information, to control an automatic repair or automatic replacement of the component (e.g., by means of a stationary or mobile service robot) and / or a software code associated with the component. Alternatively or additionally, the operation of the modular container treatment system can be automatically adjusted such that the component is bypassed by the containers and / or a software code associated with the component is bypassed, preferably while the component or the software code associated with the component is automatically replaced or repaired.Alternatively or additionally, the control system can automatically decouple the container handling sub-module (and / or main container handling module) containing the component. This allows the container handling system to react autonomously to malfunctions. Accordingly, production can be carried out with less scrap and fewer malfunctions requiring machine downtime, thus increasing overall equipment effectiveness.

[0024] In a further embodiment, the plurality of container treatment sub-modules comprise at least one of: at least one labeling sub-module for labeling the containers; at least one inspection sub-module for inspecting the containers; at least one printing sub-module for printing the containers; at least one cleaning sub-module for cleaning the containers; at least one filling sub-module for filling the containers; at least one closing sub-module for closing the containers; at least one heating sub-module for heating preforms of the containers; at least one forming sub-module for forming the containers from preforms, preferably by means of stretch blow molding; at least one turning sub-module for turning the containers over; at least one cooling sub-module for cooling the containers; at least one coating sub-module for (e.g.Internal) coating of the containers; at least one pasteurization module for pasteurizing the containers; at least one drying module for drying the containers; at least one grouping module for grouping the containers; at least one packing module for packing the containers; at least one palletizing module for palletizing the containers; at least one depalletizing module for depalletizing the containers; at least one unpacking module for unpacking the containers; and at least one dating module for dating the containers.

[0025] In a further exemplary embodiment, at least one inspection submodule and at least one labeling submodule and / or printing submodule are included, which are jointly coupled to a plurality of submodule interfaces of one of the plurality of container treatment main modules, preferably to form a container equipment main module. Advantageously, these functionally related submodules can thus be combined in a container treatment main module to form a functional unit. In a further exemplary embodiment, a plurality of filling submodules and a plurality of closing submodules are included, which are jointly coupled to a plurality of submodule interfaces of one of the plurality of container treatment main modules, preferably to form a container filling and closing main module. Advantageously, these functionally related submodules can thus be combined in a container treatment main module to form a functional unit.

[0026] In a further embodiment, several heating submodules and several forming submodules are included, which are jointly coupled to several submodule interfaces of one of the several container processing main modules, preferably to form a container manufacturing main module. These functionally related submodules can thus advantageously be combined in a container processing main module to form a functional unit.

[0027] In one embodiment, the control system comprises a plurality of decentralized control units assigned to the main conveyor module and / or the plurality of container treatment sub-modules (and / or preferably the plurality of main container treatment modules), and optionally a central data source. Preferably, the plurality of decentralized control units and the optional central data source are designed to jointly coordinate the adaptation of the operation of the modular container treatment system when coupling and / or uncoupling one of the plurality of container treatment sub-modules (and / or when coupling and / or uncoupling one of the plurality of main container treatment modules) for the purpose of self-configuring the control system. For example, parameters and / or mechatronics (e.g., automatic format part changeover) can be adapted. Preferably, type-dependent data, production-dependent data, and / or system data can be stored in the central data source.

[0028] In a further embodiment, the multiple submodule interfaces each have an electrical connection, a communication connection, a fluid connection, and / or a mechanical connection. Alternatively or additionally, the multiple submodule interfaces can be identical in design, for example.

[0029] Optionally, the plurality of sub-module interfaces can be arranged one after the other in series along a path of the conveyor sub-module of the respective container treatment main module.

[0030] It is possible for the multiple main module interfaces to each have an electrical connection, a communication connection, a fluid connection, and / or a mechanical connection. Alternatively or additionally, the multiple main module interfaces can be structurally identical. Alternatively or additionally, the multiple main module interfaces are arranged consecutively in series along a path of the main conveyor module.

[0031] In one embodiment, the main conveyor module is located centrally in the container processing system. Alternatively or additionally, the main conveyor module is designed as a transport carousel, a long-stator or short-stator linear drive conveyor, a planar drive conveyor, a belt conveyor, or a neck-handling conveyor. Alternatively or additionally, the multiple container processing submodules and / or the multiple container processing main modules are arranged distributed around the main conveyor module.

[0032] Optionally, the multiple conveyor submodules can each be designed as bypass lines to a section of the main conveyor module, as carousels or as satellites.

[0033] Preferably, a plurality of the container treatment sub-modules are arranged distributed around the conveying sub-module of the respective container treatment main module.

[0034] A further aspect of the present disclosure relates to a method for producing a modular container treatment plant, preferably as disclosed herein, using a modular construction kit. The method comprises (e.g., computer-aided) selection of a main conveyor module from a plurality of different main conveyor modules of the modular construction kit, preferably using a graphical user interface. The plurality of different main conveyor modules can each be arranged to convey containers through the modular container treatment plant. The plurality of different main conveyor modules each have a plurality of main module interfaces. The method further comprises (e.g., computer-aided) selection of a plurality of main container treatment modules from a plurality of different main container treatment modules of the modular construction kit, preferably using the graphical user interface.The plurality of different container processing main modules can be coupled to the plurality of main module interfaces (e.g., automatically by means of a driverless transport vehicle). The plurality of different container processing main modules each have a plurality of sub-module interfaces. The plurality of different container processing main modules each have a conveyor sub-module that can be connected to the selected conveyor main module for receiving the containers from the selected conveyor main module and for transferring the containers back to the selected conveyor main module. The method further comprises (e.g., computer-aided) selection (e.g., each) of a plurality of container processing sub-modules from a plurality of different container processing sub-modules (e.g., for the selected container processing main modules) of the modular system, preferably by means of the graphical user interface.The plurality of different container processing submodules can be coupled to the multiple submodule interfaces (e.g., automatically using an automated guided vehicle). The method further comprises (e.g., computer-aided) assembly (and, for example, assembly) of the modular container processing system from the selected main conveyor module, the selected main container processing modules, and the selected container processing submodules. Advantageously, the method can achieve the same advantages as those already described with regard to the modular container processing system.

[0035] It is possible that (among other things) several identical container treatment sub-modules and / or several identical container treatment main modules are selected.

[0036] Preferably, the various container processing submodules may differ in function, design, and / or configuration. Alternatively or additionally, the various main container processing modules may differ in function, design, and / or configuration.

[0037] It is possible for the method to further comprise (e.g., computer-aided) selection of a parking station and / or a driverless transport vehicle for transporting the plurality of container treatment sub-modules and / or the container treatment main modules, preferably by means of a graphical user interface.

[0038] A further aspect of the present disclosure relates to a method for operating a modular container treatment plant, preferably as disclosed herein, comprising automatically adapting the operation of the modular container treatment plant by self-configuring the control system depending on a coupling and / or uncoupling of at least one of the plurality of container treatment submodules. Optionally, the method may further comprise, for example, automatically adapting the operation of the modular container treatment plant by self-configuring the control system depending on a coupling and / or uncoupling of at least one of the plurality of main container treatment modules. Advantageously, the method can achieve the same advantages as those already described with regard to the modular container treatment plant.Preferably, the method may further comprise transporting one of the plurality of container treatment submodules between a parking station and one of the plurality of submodule interfaces by means of a driverless transport vehicle controlled by the control system in dependence on received production order information and / or received fault information.

[0039] Optionally, the method may further comprise transporting one of the plurality of container handling main modules between a parking station and one of the plurality of main module interfaces by means of a driverless transport vehicle controlled by the control system in dependence on received production order information and / or received fault information.

[0040] Preferably, the container treatment plant can be designed for producing, cleaning, coating, testing, filling, closing, labeling, printing and / or packaging containers for liquid media, preferably beverages or liquid foodstuffs.

[0041] For example, the containers can be designed as preforms, bottles, cans, canisters, cartons, flacons, etc.

[0042] Preferably, the terms "control unit" and "control system" can refer to electronics (e.g., with microprocessor(s) and data memory) that, depending on its design, can perform control tasks and / or regulation tasks and / or processing tasks. Even if the term "control" is used herein, it can also appropriately include or mean "regulation" or "control with feedback" and / or "processing."

[0043] The previously described preferred embodiments and features of the invention can be combined with one another as desired.

[0044] Short description of the characters

[0045] Further details and advantages of the invention are described below with reference to the accompanying drawings. They show:

[0046] Figure 1 is a schematic representation of a modular system for a modular container treatment plant;

[0047] Figure 2 shows a schematic representation of a modular container treatment plant according to an embodiment of the present disclosure; Figure 3 shows a schematic representation of a modular container treatment plant according to an embodiment of the present disclosure;

[0048] Figure 4 is a schematic representation of a modular container treatment plant according to an embodiment of the present disclosure; and

[0049] Figure 5 is a schematic representation of a communication network of a modular container treatment plant.

[0050] The embodiments shown in the figures correspond at least partially, so that similar or identical parts are provided with the same reference numerals and for their explanation reference is also made to the description of the other embodiments or figures in order to

[0051] To avoid repetitions.

[0052] Detailed description of exemplary embodiments

[0053] Figure 1 shows a modular system 10 for manufacturing a container treatment plant. The modular system 10 comprises several different main conveyor modules 12-16, several different main container treatment modules 18-22, and several different container treatment submodules 24-44.

[0054] The main conveyor modules 12-16 can be arranged to convey containers through a container processing system. Preferably, the main conveyor modules 12-16 can be arranged centrally in the container processing system. The main conveyor modules 12-16 can be designed in different ways.

[0055] For example, the conveyor main module 12 can be designed as a long stator or short stator linear drive.

[0056] The conveyor can be designed as a conveyor. The main conveyor module 12 can have several movement devices, or movers or shuttles, for container transport. Each movement device can transport one or more containers. The movement devices can be guided along a preferably revolving guideway, e.g., by means of rollers or sliding blocks. The movement devices can be driven independently of one another along the guideway by means of magnetic interaction between permanent magnets and electromagnets (= short stator or long stator).

[0057] The main conveyor module 14 can be designed as a conveyor belt. The conveyor belt can support the containers at the bottom and transport them using a circulating conveyor belt. The conveyor belt can be designed, for example, as a continuous belt or as a mat chain, etc. Alternatively, the main conveyor module 14 can be designed, for example, for continuous container transport in neck handling, e.g., using a container clamp.

[0058] The main conveyor module 16 can be designed as a transport star or a transport carousel. The transport star can transport the containers rotating around a central axis. The transport star can hold the containers during transport, for example, with clamps, grippers, and / or (e.g., rotary) plates.

[0059] It is possible, for example, for another main conveyor module to be designed as a planar drive conveyor or a planar motor conveyor. In this case, several movement devices, movers, or shuttles for container transport can be moved independently of one another with at least two degrees of freedom (x-direction and y-direction) over a preferably planar drive surface by means of magnetic interaction with the drive surface. It is also possible for a lifting movement (z-direction) and / or a tilting movement of the movement devices relative to the drive surface to be possible by means of the magnetic interaction. The drive surface can preferably be oriented horizontally or vertically. Each movement device can transport one or more containers.

[0060] The main conveyor modules 12-16 each have a plurality of main module interfaces 51 (shown only schematically in Figure 1). The main module interfaces 51 can be distributed around the main conveyor modules 12-16, preferably on an outer circumference of the respective main conveyor module 12-16. A container treatment main module 18-22 can be coupled to each main module interface 51. The main module interfaces 51 can, for example, each have an electrical connection, a communication connection, a fluid connection, and / or a mechanical connection. The main module interfaces 51 can preferably be structurally identical. The main module interfaces 51 can be arranged one after the other in series along a course of the respective main conveyor module 12-16.

[0061] The containers can be treated in the main container treatment modules 18-22. The main container treatment modules 18-22 can be coupled (docked) to the main module interfaces 51 of the main conveyor modules and detached (undocked) from them, preferably automatically. The main container treatment modules 18-22 can each have a conveyor submodule 46, 48, 50 for container transport and several submodule interfaces 52. Several of the container treatment submodules 24-44 can be coupled to the submodule interfaces 52, preferably one container treatment submodule 24-44 per submodule interface 52. Using the submodule interfaces 52, the main container treatment modules 18-22 can be equipped with the desired container treatment submodules 24-44.

[0062] The conveyor submodules 46, 48, 50 can transport the containers and / or the container processing submodules 24-44 with which the respective main container processing module 18-22 is equipped. The conveyor submodules 46, 48, 50 can be connected to receive the containers from one of the main conveyor modules 12-16 and (after container processing) to transfer the containers back to the main conveyor module 12-16. The conveyor submodules 46, 48, 50 can be designed differently.

[0063] The conveyor submodule 46 can be designed, for example, as a synchronously operated satellite, e.g., a synchronously operated transport star or carousel. The conveyor submodule 48 can be designed, for example, as a bypass section for a section of the respective main conveyor module. The conveyor submodule 48 can preferably be designed as a long-stator or short-stator linear drive or planar drive conveyor. The conveyor submodule 50 can be designed, for example, as a continuously operated transport star or carousel.

[0064] The submodule interfaces 52 can be distributed around the conveyor submodules 46-50. A container treatment submodule 24-44 can be coupled (docked) to and detached (undocked) from each of the submodule interfaces 52. The submodule interfaces 52 can, for example, each have an electrical connection, a communication connection, a fluid connection, and / or a mechanical connection. Preferably, the submodule interfaces 52 can be structurally identical. The submodule interfaces 52 can be arranged one after the other in series along the path of the respective conveyor submodule 46-50.

[0065] The container processing submodules 24-44 can each be coupled to one of the submodule interfaces 52. Depending on their design, the container processing submodules 24-44 can be stationary or moved by the respective conveyor submodule 46-50. The container processing submodules 24-44 can be carried by supports of the main container processing modules 18-22. The container processing submodules 24-44 can be designed differently. The container processing submodules 24-44 can be divided into basic functions, such as coating, labeling, filling, etc.

[0066] For example, the heating sub-module 24 can be designed to heat preforms to produce the containers. The forming sub-module 26 can be designed to form the containers. For example, the forming sub-module 26 can (e.g., stretch-) blow mold containers from preforms. The cooling sub-module 28 can be designed to cool the containers. The turning sub-module 30 can be designed to turn (invert) or turn the containers upside down. The coating sub-module 32 can be designed to coat the containers (e.g., internally). The printing sub-module 34 can be designed to print on the containers, e.g., using a direct printing process. The labeling sub-module 36 can be designed to label the containers. The inspection sub-module 38 can be designed to inspect or test the containers. The cleaning sub-module 40 can be designed to clean the containers (e.g., overhead). The filling submodule 42 can be designed to fill the containers, e.g.with a liquid or pasty medium. The closure submodule 44 can be designed to close the containers, e.g., with a lid, a screw cap, a cork, or a crown cap.

[0067] To improve the efficiency of the modular system 10, the production or provision of the modules 12-50 can preferably be adapted depending on the frequency of use in container treatment systems. Thus, the modules 12-50 and their respective components can be provided, for example, as basic modules, order-specific modules, or special modules.

[0068] Those modules from modules 12 to 50 that are versatile, frequently required, and, for example, have easily predictable sales figures can be provided as base modules. Ideally, base modules can be pre-produced according to sales forecasts and easily retrieved when an order is received. Their mechatronic design is preferably designed so that, after retrieval from the warehouse, no or very few adjustments are required before a base module can be connected to other modules.

[0069] Those modules from modules 12 to 50 that are required for specific processes / functions and, for example, have difficult-to-predict sales figures can be provided as order-specific modules. Order-specific modules can preferably be manufactured specifically for specific orders. Unlike special modules, their functional scope can be developed for series production and included permanently in the product portfolio. The basic modules, and preferably also the order-specific modules, can be pre-assembled by the manufacturer based on forecast data, independent of the order and object. This can reduce manufacturing costs, shorten delivery times, and improve responsiveness to short-term changes.

[0070] Those modules from modules 12 to 50 that are not yet fully developed variants of modules or modules with entirely new functions can be provided as special modules. For special modules, a custom development can be carried out, the impact of which on the order can ideally be communicated to the customer during the planning of the container treatment plant, e.g., regarding the possibilities and limitations of the special module, additional costs, increased delivery times, etc., if known or estimable.

[0071] For example, a container handling main module 22 designed as a container filling main module can have, as a base module, the conveying submodule 50 designed as a carousel with a predetermined pitch circle. The filling submodules 42 with which the container filling main module is equipped can be order-specific modules with filling valves, etc., adapted for the respective application (e.g., with or without a load cell, fill level probe, and / or aseptic filling). As a further order-specific module, the container filling main module can, for example, be equipped with a media supply module for supplying the filling submodules 42 with a filling medium or product. The media supply module can optionally also supply compressed air to the filling submodules 42 and / or provide a vacuum source for evacuating the containers via the filling submodules 42.The container filling main module 22 can also be equipped with a special tank module for the filling medium, which is adapted as a special module to the spatial conditions of the desired production location.

[0072] It is understood that the example explained above can be transferred to other container handling main modules, such as a container labeling main module.

[0073] To construct or manufacture a modular container treatment system, preferably one main conveyor module can be selected from the multiple main conveyor modules 12-16 of the modular construction system 10. In addition, multiple main container treatment modules are selected from the main container treatment modules 18-22 and multiple container treatment submodules 24-44 are selected to equip each of the selected main container treatment modules. The container treatment system is then modularly assembled and constructed from the selected main conveyor module, the selected main container treatment modules, and the selected submodules. The selected main conveyor module 12 and the selected main container treatment modules 18-22 coupled to it (without the submodules 24-44) can form a functionally neutral or functionally adaptable basic structure of a modular container treatment system.By connecting the selected container processing submodules 24-44, an order-specific container processing system can be provided. The container processing submodules 24-44 can also be integrated into the basic structure depending on a production order (or production order information). Depending on the product, the configuration of the container processing system can be easily and quickly modified.

[0074] The selection of the main conveyor modules 12-16, the main container handling modules 18-22, and the container handling submodules 24-44 can preferably be carried out computer-assisted using a graphical user interface on a computer. Using the graphical user interface, various information can be entered and retrieved, e.g., data on preforms, containers, container formats, labels and / or closures, etc. Optionally, completely or partially preconfigured container handling systems, e.g., from previous sessions or orders, can also be loaded into the graphical user interface. Customers can thus develop or refine their specific requirements directly in the graphical user interface.

[0075] Using the graphical user interface, a desired configuration for the container treatment plant can then be created. Optionally, product specialists can adapt details or special customer requests. It is also possible to take the spatial installation conditions into account when planning the container treatment plant in the graphical user interface. For example, a production hall for the container treatment plant can be measured using a 3D scan, and the data can then be loaded into the graphical user interface. The dimensions of the production hall can also be available as CAD data and loaded into the graphical user interface.

[0076] When planning the container treatment plant in the graphical user interface, even late changes to modules can be taken into account due to the modular nature of the modular system 10. It is also possible—if the container treatment plant is planned with correspondingly variable modules—for the container treatment plant to provide a certain degree of variability for treating different containers. The graphical user interface can further support the user in planning the container treatment plant, for example, by displaying additional information for specific actions or changes relating to the container treatment plant. For example, it can show the effects of a specific change on constraints such as plant size, costs, delivery date, expandability, flexibility, and / or performance, etc.In this context, special customer requests can also be accommodated, with the effects on the order constraints preferably being directly visible and clearly communicated via the graphical user interface.

[0077] The graphical user interface can also actively support the user in planning, e.g., by displaying suggestions for improvement, highlighting other options and / or features, etc., so that the user can advantageously assemble the optimal container treatment system for their application in a modular manner.

[0078] Based on the data from the container processing system compiled in the graphical user interface, the system manufacturer can also quickly prepare a quote for the customer, resulting in significant time and resource savings compared to conventional quotation preparation. The manufacturer can also benefit from easier planning of required quantities of machines and systems, as well as faster order processing thanks to standardized modules.

[0079] After digitally assembling the container processing system in the graphical user interface, the container processing system can be physically assembled and installed using the modular system 10. Autonomous and, where appropriate, semi-autonomous modules can be commissioned prior to delivery, so that they are already prepared for mechanical, control, and software integration into the system at the customer's site. As already explained, the individual modules can be provided, for example, as basic modules, order-specific modules, or special modules.

[0080] The respective container treatment plant can have a (e.g., centralized or distributed) control system. The control system can advantageously enable the respective container treatment plant to be controlled in a self-configuring manner, as described in detail below by way of example. Optionally, the control system can also enable the respective container treatment plant to be self-organizing, self-optimizing, self-protecting, self-healing, and / or self-explanatory, or to be controlled in a self-organizing, self-optimizing, self-protecting, self-healing, and / or self-explanatory manner, as also described in detail below by way of example.With regard to the self-configuration capability, the control system can automatically adapt operation of the respective container treatment plant depending on coupling at least one of the plurality of container treatment submodules 24-44 to at least one of the submodule interfaces 52 and / or decoupling of at least one of the plurality of container treatment submodules 24-44 from at least one of the submodule interfaces 52. Optionally, the control system can automatically adapt operation of the respective container treatment plant depending on coupling at least one of the plurality of container treatment main modules 18-22 to at least one of the main module interfaces 51 and / or decoupling of at least one of the plurality of container treatment main modules 18-22 from at least one of the main module interfaces 51.

[0081] The ability for self-configuration can be implemented, for example, by each module 12-50 "knowing" its own configuration, e.g., in the form of configuration information stored in a respective assigned control unit, and transmitting this configuration information to the other modules 12-50 of the respective container treatment system upon connection. On the other hand, each module can also receive configuration information by exchanging it with other modules 12-50 of the respective container treatment system. In terms of software, this can be implemented, for example, in such a way that parameter sets and functions for a specific production type or for the production of a specific product can be loaded fully automatically from a suitable source. If possible and appropriate, the mechanics of a module 12-50 can also be adapted to the respective production mode.

[0082] Preferably, the control system of the respective container treatment plant can be implemented in a decentralized or distributed manner. The control system can, for example, comprise decentralized control units assigned to the respectively selected conveyor module 12-16 and 46-50 as well as to the respectively selected treatment modules 18-44. For example, each module 12-50 of the respective container treatment plant can have its own decentralized control unit. The decentralized control units can communicate with each other. The control system can optionally also have a central data source 72 (see Figure 5) with which the decentralized control units can communicate and / or specifically retrieve and modify information.

[0083] The decentralized control units and the central data source 72 can jointly coordinate the adjustment of the operation of the respective container treatment systems when coupling and / or uncoupling one of the multiple modules 18-50 for self-configuration of the control system. For example, a control unit assigned to a coupling module can transmit information regarding its own configuration (e.g., software and / or hardware) to the other decentralized control units and / or the central data source 72. Alternatively or additionally, a control unit assigned to a coupling module can receive information regarding the configuration (e.g., software and / or hardware) of the container treatment system and / or other modules 12-50 from the central data source 72 and / or other decentralized control units.

[0084] The ability of the control system to self-configure can play a crucial role even during the assembly of the container treatment plant. Final assembly of the container treatment plant takes place directly at the customer's site. Self-configuration enables the assembled modules 12–50 to automatically recognize and communicate with each other. Interfaces are available for integrating third-party machines that do not originate from the modular system 10. Commissioning of the container treatment plant created from the modular system 10 can be completed in a very short time. To further accelerate commissioning, a virtual commissioning of the process, control system, and mechanical components can be performed beforehand based on a virtual twin of the container treatment plant, which has been compiled in the graphical user interface.

[0085] With its ability to self-organize, the control system can control a process, work, or program-based operational sequence for operating the respective container treatment plant, preferably taking into account all connected modules 18–50. For example, higher-level production order information can be received by the control system, and each module 12–50 of the respective container treatment plant can perform its function to solve the task specified by the production order information. This eliminates the need to plan the configuration of the respective container treatment plant and the scheduling of functions, program them in advance, and completely revise them in the event of changes or optimization. Instead, the control system can automatically adapt the current operation of the respective container treatment plant to a current configuration (e.g., which modules 18–50 are connected?).

[0086] The modular system 10 can optionally also include a parking station or a modular station

[0087] 54 and at least one driverless transport vehicle (AGV - automated guided vehicle) 56. In the parking station 54, uncoupled container processing submodules 24 - 44 of a respective container processing plant that are not currently in use can be temporarily stored. It is also possible for one or more uncoupled container processing main modules 12 - 16 of a respective container processing plant that are not currently in use to be temporarily stored in the parking station 54. The modules 18 - 22 and / or 24 - 44 temporarily stored in the parking station 54 can be used, for example, when coupled container processing submodules 24 - 44 that require repair or maintenance are to be replaced and / or when they are required to fulfill received production order information, e.g., for a different product, a different container format, or a different treatment.

[0088] By means of the driverless transport vehicle 56, the container processing submodules 24-44 of a respective container processing system can be transported between the parking station 54 and the submodule interfaces 52. Alternatively or additionally, the container processing main modules 18-22 of a respective container processing system can be transported between the parking station 54 and the main module interfaces 51 by means of the driverless transport vehicle 56.

[0089] The driverless transport vehicle 56 can be controlled by the control system of the respective container treatment plant. Alternatively or additionally, the transport vehicle 56 can also be assigned its own decentralized control unit located in the communication network. For example, the control system of the respective container treatment plant can receive production order information for treating the containers. The production order information can, for example, be entered by a user or received via a communication interface. The production order information can, for example, specify how the containers or which containers are to be treated, e.g. with regard to a desired filling product, a desired closure, a desired container format, a desired labeling, a desired print and / or a desired packaging, etc. Optionally, the production order information can, for example,specify the number of containers to be treated.

[0090] Depending on the received production order information, the control system can control the automated guided vehicle 56 such that all previously uncoupled container processing submodules 24-44 and / or main container processing modules 18-22 of the respective container processing system that are still required to fulfill the production order information are transported from the parking station 54 to the submodule interfaces 52 or the main module interfaces 51 by means of the automated guided vehicle 56 and optionally also coupled (e.g., automatically). On the other hand, if desired, at least one previously coupled container processing submodule 24-44 and / or main container processing module 18-22 of the respective container processing system that is not required to fulfill the production order information can be uncoupled (e.g., automatically) and transported to the parking station 54 by means of the automated guided vehicle 56.

[0091] It is understood that, in addition to the modules 12 - 44, the parking station 54 and the driverless transport vehicle 56 can also be selected for constructing or manufacturing a modular container treatment plant.

[0092] Alternatively or in addition to the driverless transport vehicle 56, it is also possible for the container handling submodules 24-44 to be manually coupled, uncoupled, and / or transported. It is understood that auxiliary means such as vehicles (e.g., an industrial truck) can also be used for this purpose.

[0093] With regard to the ability to self-optimize, the control system can be designed in such a way that a database is created and utilized. For example, target order values ​​can be fed into the control system using production order information. Through self-configuration, the output parameters or operating parameters for each module 12 - 50 can be known, which can then be adjusted fully automatically by the control system during operation to optimally fulfill the task. Signals from corresponding sensors, as well as the monitoring of process parameters and comparison with a database of empirical values ​​and optimization measures from the past, can serve as references for such optimization processes. It is possible to make this knowledge base accessible to a large number of container treatment plants worldwide and to gradually enrich it with newly acquired data, thus creating a continuous improvement process.The container treatment plant can also advantageously determine its optimal production process taking into account criteria such as minimal energy and media consumption.

[0094] Specifically, it may be possible for the control system of the respective container treatment plant to automatically adapt its operation depending on the received production order information for treating the containers. To do so, the control system may, for example, generate a movement path of the containers through the respective container treatment plant, incorporating at least some of the plurality of main container treatment modules 18-22 and / or container treatment sub-modules 24-44. Movement of the containers through the container treatment plant can then be controlled by the control system according to the generated movement path. Adapting the operation may also include adjusting the operating parameters of the modules 12-50. It is also possible for the control system to draw on empirical data in which previous operations of the respective container treatment plant and / or other container treatment plants are stored to adapt the operation.

[0095] With regard to self-protection capabilities, the control system of the respective container treatment plant can be configured to detect current or impending errors or defects based on the information it receives. If an error is detected, the control system can initiate appropriate protective measures to minimize the extent of damage. Ideally, no operator action is required. The control system can receive the information, for example, from sensors and / or operating parameter monitoring. When evaluating the information, the control system can also access a database of empirical values.

[0096] With regard to the self-healing capability, the control system can be configured, based on received information, to adapt the operation of the respective container treatment system in the event of errors or defects that occur, for example, which are unpredictable or unavoidable, such that the respective container treatment system can continue to operate to treat the containers until the defect can be repaired and / or during this time the defect can be repaired during ongoing operation. The control system can receive the information, for example, from a sensor system and / or an operating parameter monitor. When evaluating the information, the control system can also access a database containing empirical values, for example.

[0097] In detail, it may be possible for the control system of the respective container treatment plant to receive fault information. The fault information may, for example, indicate a predicted or current defect in a component. The component may, for example, be included in one of the components 12 - 56. The information may, for example, be transmitted to the control system by a sensor system of the respective container treatment plant. The sensor system can monitor the component. The sensor system may, for example, have physical sensors, e.g., optical sensors. Alternatively or additionally, the sensor system may have virtual sensors, which, for example, can use recorded operating data to infer a current or impending defect in a component. Alternatively or additionally, the information can be entered by a user and / or received via a communication interface. Based on the received fault information, the control system can, for example,control an automatic repair or automatic replacement of the component. For the automatic replacement, the control system can, for example, control the automated guided vehicle 56. Alternatively or additionally, the control system can automatically adapt the operation of the respective container handling system based on the received fault information to bypass the component specified in the fault information, preferably while the component is being automatically replaced or repaired.

[0098] For clarification, two examples of possible malfunctions are described below.

[0099] In the first example, a faulty clamp holding a container causes a disruption in the inlet of a container handling main module or sub-module for labeling. Due to the defective clamp, the containers cannot be labeled any further. In this case, the respective container handling system can operate in a self-protective manner, which can prevent most errors and malfunctions before they occur. If, for example, the clamp shows signs of impending failure, e.g., decreasing clamping force, this can be detected by a sensor in the container handling system and a fault message can be transmitted to the control system. The control system can either indicate to an operator that the clamp needs to be replaced and / or control a movable service robot to replace the clamp.To achieve self-healing, the control system can first redirect the container flow to at least one other container handling main or sub-module for labeling, bypassing the defective clamp, while the defective clamp is being replaced, e.g., by the service robot. This not only prevents downtime, but in the best case scenario, the entire container handling system can continue running at full capacity. Operator intervention is also ideally not required. Buffer lines can be dispensed with in the container handling system if desired, as the flexible container transport can ensure supply to each module.

[0100] In the second example of a malfunction, a bottle breaks in a main container treatment module or sub-module for filling containers. For example, in glass fillers, glass breakage can repeatedly occur during filling due to excessive temperature gradients. This means that a bottle shatters during filling and the surrounding bottles can also be damaged. The control system can check the containers upstream of the main container treatment module or sub-module for filling, for example using suitable sensors and / or a database. This can record data on the material, temperature and / or previously completed filling cycles, for example. The control system can therefore preferably adapt the container treatment to the recorded data. In a self-configuring and self-protecting manner, the heating sub-modules 24 can, for example, be used to control slower heating of the containers than during normal operation, so that, for example,Stress peaks in the structure can be prevented and thus the probability of fracture is reduced.

[0101] With regard to self-explanatory capability, the container handling system can make processed and exchanged data and information available to the operator of the respective container handling system via a user interface. This preferably allows every status, every piece of information, and every instruction to be made available to the operator at the right time and in the right place in a fully understandable manner, enabling them to understand the operation of the container handling system and, at the same time, to manually adjust it. Simplified operability can advantageously lead to lower personnel costs and fewer operating errors. When problems arise, an operator can be guided through finding and resolving solutions, thereby enabling shorter downtimes and increasing overall equipment effectiveness.

[0102] Modules 12–50 and their assemblies can exhibit varying degrees of autonomy. For example, modules 12–50 and their assemblies can be designed as (fully) autonomous, semi-autonomous, or partially non-autonomous modules. The specific design can depend on various factors, such as reusability in other peripherals, procurement / outsourcing of entire functions, costs, technical requirements and constraints, advantages in the manufacturing process (assembly, production, commissioning), etc. Preferably, the term "autonomous" in this context means that there is no need for interconnection with other modules, but with the provision of all media, environmental requirements, resources, etc. required for function, such as power / performance, data, fluids, mounting / stabilization, consumables, workpieces, etc.

[0103] Autonomous modules can enable the self-configuration described above and, optionally, also self-organization, self-optimization, self-protection, self-healing, and / or self-explanation. Autonomous modules can perform one or more functions either individually or in a network. Accordingly, an autonomous module can already have the necessary mechanics, electrical hardware, and associated software (including module-specific parameters) to perform the respective task on board ex works, or can, for example, request program blocks or data sets or download them from a suitable location. The ability to communicate, request, forward, and exchange information, add or uninstall software modules, etc., may be necessary for exchanges between modules, but also with the system operator and with external systems.This type of consistent data availability is intended to create transparency and simplicity in using the system for everyone who interacts with it.

[0104] Semi-autonomous modules, which can also be referred to as information-providing modules, can optionally carry out calculations independently, control actuators, request information and / or change their configuration, etc. Semi-autonomous modules can advantageously be used as flexibly deployable, self-contained units that fulfil a sub-task or provide data for other modules or the higher-level task. For such a sub-task or a semi-autonomous module, stand-alone commissioning or autonomous operation is in many cases not possible or does not make sense, for example because commissioning is very short and can therefore be carried out in a network, or the effort required to simulate the necessary module peripherals is very high. An example of this would be a sensor or evaluation module, where the intelligence orThe logic of an autonomous module initiates certain measures and actions. A gripper attachment that can report its type and operating time and provides an "open / closed" status signal (upon request) could also be such a module.

[0105] Non-autonomous modules, which can also be referred to as carrier assemblies / modules, are purely or almost purely mechanical assemblies that, for example, only represent a carrier element and, by means of a code or data storage, etc., only provide the most necessary information such as type, part number, date of manufacture, etc. This module type does not fulfill all functions on its own, but can be understood as support for the implementation of a module 12 - 50.

[0106] In addition to the autonomous, semi-autonomous, and non-autonomous modules, third-party modules can also be installed in the container treatment plant. These can be procured from third parties and integrated into the fully modularized system via an appropriate interface, allowing them to communicate within the same network.

[0107] The modular system 10 can significantly simplify conversion or retrofitting even after the initial commissioning of the assembled system. It should first be noted that the individual modules 12-50 can already exhibit a certain degree of variability with regard to the containers that can be transported or treated. For example, all containers of a certain type with a volume between 0.3 l and 1 l can be treated. This variability can preferably be provided purely via software, so that, for example, a change to a new bottle format can be made at the touch of a button. For this purpose, a certain number of memory slots in which the data for the different containers is stored can be provided ex works. The number of memory slots can be expanded, depending on requirements.

[0108] In addition to the software upgrade, as explained above, it may also be necessary to upgrade the hardware, for example, for specific container formats or products. For this purpose, modules 12–50 can simply be connected to the interfaces 51, 52 as required, e.g., using mobile robotics, such as the automated guided vehicle 56, with appropriate tools, or by an on-site plant operator.

[0109] Thanks to the preferred holistic interfaces 51, 52 (mechanics, automation / electrics, and software) and the ability to self-configure and, if necessary, self-organize, modules 12–50 can be replaced during the product lifecycle, or the system can be expanded with new modules and their functions. Reasons for such measures could be a desired performance increase / decrease (e.g., to adapt a system to the current market situation), a technology change / addition (e.g., printing instead of labeling or additional PET inner coating), an expansion for greater product and format flexibility (e.g., multiple types simultaneously on the same system), etc.

[0110] Such changes to the system can be planned or prepared in advance within the framework of the modular system 10. On the other hand, the modular system 10 also enables previously unprepared retrofitting of modules 12 - 50 during the product life cycle.

[0111] The graphical user interface is the preferred option for planning retrofits. This allows feedback, for example, on which hardware and software are necessary for the requested changes. If all mechanical engineering requirements are already met, the change can simply be enabled via software. Otherwise, the corresponding modules 12–50 can be manufactured and transported to the system. This approach not only allows the system itself to be upgraded, but also—if available—a mobile robotics system (e.g., driverless transport vehicle 56) that supports or completely takes over processes within the system. Thanks to the modular system 10, modules 12–50 that are no longer required can also be easily integrated into other systems assembled using the modular system 10 and thus reused.

[0112] In the previously described embodiment, the modular system 10 comprises a plurality of container treatment main modules 18-22 and a plurality of container treatment submodules 24-44 for equipping the container treatment main modules 18-22. However, it is also possible in principle for the modular system 10 to comprise only the container treatment submodules 24-44 and, for example, not to comprise any connectable and detachable container treatment main modules 18-22. In this case, the submodule interfaces 52 for the container treatment submodules 24-44 could be arranged, for example, on the conveyor main module 12 or otherwise.

[0113] Figures 2 to 4 show different container treatment systems that can be constructed, for example, using the modular system 10 of Figure 1.

[0114] It is understood that even if only the exemplary container treatment plant of Figure 2 is shown with a parking station 54 and a driverless transport vehicle 56, the container treatment plants of Figures 3 and 4 can also have a parking station 54 and a driverless transport vehicle 56, if desired.

[0115] It is also understood that functions and configurations which are explained below only with regard to one of the container treatment systems of Figures 2 to 4 can be implemented equally in the other container treatment systems of Figures 2 to 4.

[0116] It should also be noted that the variants shown in Figures 2 to 4 are only a selection of the possibilities enabled by the modular system 10. The variants and combination options of the modular system 10 are far more extensive and can be adapted to the individual customer. It is irrelevant for the design itself whether the customer requires a full line, a partial line, or just individual machines, units, or modules. The modular design allows for any combination.

[0117] In detail, Figure 2 shows a container treatment system 58. The container treatment system 58 can have the main conveyor module 12. Several main container treatment modules 20 can be coupled to the main module interfaces 51 of the main conveyor module 12, namely, for example, the main container treatment modules 20.1 to 20.7. The conveyor sub-modules 48 of the main container treatment modules 20.1 to 20.7 are each designed or arranged as bypass routes for different sections of the main conveyor module 12. From the main transport path, which is defined by the main conveyor module 12, the containers are diverted for a respective treatment via the conveyor sub-modules 48 arranged as bypasses and, after treatment, are guided back to the main transport path or the main conveyor module 12.

[0118] In the exemplary configuration shown, the container treatment system 58 can perform the functions of heating, forming / manufacturing, cooling, printing, filling, and closing. Closely linked treatment steps can be carried out sequentially in the same main container treatment module 20.1 to 20.7, if desired. This coupling of different treatment steps can occur, for example, during heating and forming (see main container treatment modules 20.1 and 20.2) and / or during filling and closing (see main container treatment modules 20.6 and 20.7).

[0119] The container processing main modules 20.1 and 20.2 can be designed as container manufacturing main modules for manufacturing containers. The container processing main modules 20.1 and 20.2 can each have a plurality of heating submodules 24 and forming submodules 26.

[0120] The container treatment main module 20.3 can be designed as a container cooling main module for cooling the containers. The container treatment main module 20.3 can have several cooling submodules 28.

[0121] The container processing main modules 20.4 and 20.5 can be designed as container equipment main modules for equipping the containers. The container processing main modules 20.4 and 20.5 can each have several printing submodules 34 (and / or labeling submodules 36 - not shown).

[0122] The container processing main modules 20.6 and 20.7 can be designed as container filling and closing main modules. The container processing main modules 20.6 and 20.7 can each have a plurality of filling submodules 42 and a plurality of closing submodules 44.

[0123] The arrangement of the container processing main modules 20.1 to 20.7 is purely exemplary. For example, the container processing main modules 20.4 and 20.5, designed as container equipment main modules, can be arranged downstream of the container processing main modules 20.6 and 20.7, designed as container closure main modules. The container processing system 58 can include the parking station 54 and the automated guided vehicle 56 for transporting the container processing main modules 20.1 to 20.7 and / or the container processing submodules 24-44 between the parking station 54 and the respective main and submodule interfaces 51, 52 (see also Figure 1).

[0124] Optionally, the container treatment system 58 can also have, for example, a preform feeder 60. By means of the preform feeder 60, preforms or preforms for the containers can be transported to the main conveyor module 12 and transferred thereto.

[0125] During operation of the container treatment system 58, preforms can be fed to the main conveyor module 12 via the preform feeder 60 and discharged via one of the two main container treatment modules 20.1 and 20.2, heated in the heating submodules 24, and formed into containers in the forming submodules 26. The manufactured containers are transferred back to the main conveyor module 12 by the conveyor submodules 48.

[0126] Using sensory temperature detection, containers that are hotter than a predefined limit can be diverted to the main container treatment module 20.3 for cooling by means of the cooling submodules 28 and, after cooling, returned to the main conveyor module 12. On the other hand, containers whose temperature is below the predefined limit or within a target range can be transported further on the main conveyor module 12 without being diverted to the main container treatment module 20.3.

[0127] The printing processing steps can then be performed in the main container processing modules 20.4 and 20.5, and the filling and sealing steps can be performed in the main container processing modules 20.6 and 20.7. The containers can be distributed equally between the main container processing modules 20.4 and 20.5, as well as between the main container processing modules 20.6 and 20.7.

[0128] Unused container processing submodules 24-44 can be temporarily stored in the parking station 54 and, as needed, delivered for coupling to the interfaces 52 by means of the automated guided vehicle 56. Since, as mentioned, the control system is, among other things, self-configuring, the coupling and uncoupling of the container processing submodules 24-44 can take place without a setup process, and the operation of the container processing system 58 can be automatically adjusted accordingly. Depending, for example, on production order information received by the control system of the container processing system 58, the composition of the entire container processing system 58, i.e., the automatic coupling and uncoupling of the modules 12-44, can be self-organizing and self-optimizing in order to achieve the best possible production.By means of fault information received by the control system of the container treatment system 58, defective components or modules 12-44 can be detected (early) and replaced or repaired, for example, before a fault or damage can occur in the entire container treatment system 58. This also enables the container treatment system 58 to be capable of self-protection and self-healing.

[0129] Figure 3 shows a container treatment plant 62.

[0130] In the container treatment system 62, for example, the main conveyor module 14 designed as a conveyor belt conveyor and the main treatment modules 22.1 - 22.12 with the conveyor submodules 50 designed as a carousel can be used.

[0131] The container processing main modules 22.1 and 22.2 can be designed as container manufacturing main modules for manufacturing the containers. The container processing main modules 22.1 and 22.2 can each have a plurality of mold submodules 26.

[0132] The container treatment main modules 22.3 and 22.4 can be designed as container cooling main modules for cooling the containers. The container treatment main modules 22.3 and 22.4 can each have several cooling submodules 28.

[0133] The container processing main modules 22.5 and 22.6 can be designed as container equipment main modules for equipping the containers. The container processing main modules 22.5 and 22.6 can each have at least one inspection submodule 38 and at least one labeling submodule 36.

[0134] The container treatment main modules 22.7 and 22.8 can be designed as main cleaning modules for cleaning the containers. The container treatment main modules 22.7 and 22.8 can each have several cleaning submodules 40.

[0135] The container processing main modules 22.9 and 22.10 can be designed as container filling main modules. The container processing main modules 22.9 and 22.10 can each have a plurality of filling submodules 42. The container processing main modules 22.11 and 22.12 can be designed as container closing main modules. The container processing main modules 22.11 and 22.12 can each have a plurality of closing submodules 44.

[0136] The arrangement of the container processing main modules 22.1 to 22.12 is purely exemplary. For example, the container processing main modules 22.5 and 22.6, designed as container equipment main modules, can be arranged downstream of the container processing main modules 22.11 and 22.12, designed as container closure main modules.

[0137] During operation of the container processing system 62, continuous container transport can be provided via the main conveyor module 14. The container flow can be distributed as needed among the main container processing modules 22.1 to 22.12, enabling, for example, optimal capacity utilization. During distribution, the continuous container flow can be taken from the main container processing modules 22.1 to 22.12, for example, using clamps, and transferred back to the main conveyor module 14.

[0138] The container treatment system 62 also shows the integration of a conventional preform heating device 64 upstream of the main conveyor module 14, through which all preforms pass.

[0139] Figure 4 shows a container treatment plant 66.

[0140] In the container treatment system 66, for example, the main conveyor module 16, designed as a carousel, and the main container treatment modules 18.1 - 18.14 can be used with the conveyor submodules 46, designed as satellites (carousels), which, for reasons of clarity, are not all provided with a separate reference numeral in Figure 4. The main container treatment modules 18.1 - 18.14 are connected to the main conveyor module 16 via transport star wheels.

[0141] The container processing main modules 18.1 to 18.6 can be designed as container manufacturing main modules for manufacturing the containers. The container processing main modules 18.1 to 18.6 can each have a plurality of forming submodules 26, which, for reasons of clarity, are not all provided with a separate reference numeral in Figure 4. The container processing main modules 18.1 to 18.3 can share a transport star that connects them to the conveyor main module 16. Likewise, the container processing main modules 18.4 to 18.6 can share a transport star that connects them to the conveyor main module 16. The container processing main module 18.7 can be designed as a container equipping main module for equipping the containers. The container processing main module 18.7 can have at least one inspection submodule 38 and at least one labeling submodule 36. It is possible for the labeling submodule 36 to be interchangeable with a printing submodule 34, for example. The container handling main module 18.7 can be connected to the main conveyor module 16 via an inlet star and an outlet star.

[0142] The main container processing modules 18.8 to 18.14 can be designed as main container filling modules. The main container processing modules 18.8 to 18.14 can each have a plurality of filling sub-modules 42, which, for reasons of clarity, are not all provided with a separate reference numeral in Figure 4. The main container processing modules 18.8 to 18.11 can share a transport star that connects them to the main conveyor module 16. Likewise, the main container processing modules 18.12 to 18.14 can share a transport star that connects them to the main conveyor module 16. It is possible for the main container processing modules 18.12 to 18.14 to be designed as main container closing modules, each having a plurality of closing sub-modules 44 (not shown).

[0143] The arrangement of the container treatment main modules 18.1 to 18.14 is purely exemplary. For example, the container treatment main module 18.7, designed as a container equipment main module, can be connected to the conveyor main module 16 downstream of the container treatment main module 18.14.

[0144] With reference to Figures 2 to 4, some aspects of an exemplary production operation of the container treatment systems 58, 62, 66 are described below.

[0145] During operation, an operator can access all relevant production data at any time via central displays, head-up displays, data glasses, tablets, etc. Material supply, production, process optimization, logistics, etc. can be integrated and run without manual intervention.

[0146] Sensors in the container treatment systems 58, 62, 66 can monitor relevant key data and identify, for example, wear, productivity losses, malfunctions, process fluctuations, etc.

[0147] In this context, failure probabilities can be determined, for example, by comparing them with a digital twin. If, for example, a specified threshold is exceeded or undershot, the control system can issue a notification with instructions for intervention or, optionally, automatically order spare parts, lubricants, etc. The digital twin is preferably synchronized daily with the physical container handling system 58, 62, 66. All data is evaluated, for example, using artificial intelligence. The data sets from a large number of delivered systems can serve as the basis for continuous optimization, including the digital twins, and thus for the continuous improvement of the process parameters in each module 12 - 50.

[0148] Through this approach and the continuously growing knowledge base, modules 12-50 and their interconnected systems can optimally handle malfunctions. Foreseeable error conditions can be avoided, or their elimination can be optimally prepared and processed, preferably fully automatically. For example, appropriate robot technology can be used for this purpose, or malfunctions can be remedied by the operator under self-explanatory guidance from the respective module 12-50, e.g., the provision and replenishment of consumables just in time, wear part failure, etc.

[0149] In the case of unforeseeable errors, the error can be rectified immediately, as far as possible. For example, in the event of a software crash on a module, an automatic reboot routine can be loaded without stopping production. It is also possible to put the system into a safe state and, for example, issue a recommended course of action to the operator.

[0150] For example, a faulty module 12 - 50 can automatically disconnect from the respective main or submodule interface 51 or 52. The system can then advantageously continue production, for example, at reduced power. Using the knowledge base, it could then be determined, for example, that a leak was the cause in 92% of the current fault, and which connector should be checked / replaced.

[0151] A preferably self-organizing sequence of the overall production process enables the container handling systems 58, 62, 66 to react quickly to changes in the production plan and, with the appropriate setup on modules 12 - 50, to also process different products in different containers. With direct software coupling to the associated production planning system, it is also conceivable, for example, that the advancement of an urgent order can be specified, planning takes place fully automatically, the container handling systems 58, 62, 66 independently adapt or adjust accordingly, and the system operator is informed of what and how to do it so that the prioritized order is completed on time. It is also possible for an operator to decide during operation which digital functions or features they wish to use.For this purpose, the customer preferably has an overview of all the options available with the respective container handling system 58, 62, 66 in the previously explained graphical user interface, and can directly add, install, and, if necessary, remove corresponding additional programs and plug-ins (e.g., various process optimization programs, self-healing programs, type storage slots when using customizable accessories, etc.). Likewise, the customer can also submit suggestions for improvements to their container handling system 58, 62, 66 at any time, so that the entire system configuration can be optimized according to customer criteria and objectives (maximum overall equipment effectiveness, energy savings, longevity, etc.), and all potential can be exploited.

[0152] Figure 5 shows an exemplary communication network 68 in which the modules 12 - 50 can be integrated, as explained below using some modules as examples.

[0153] The communication network 68 can include various modules 12-50 (only some of which are shown), communication connections 70, and a central data source (central data storage) 72. Optionally, the communication network 68 can also include, for example, a packing module 74 for packing the containers.

[0154] Preferably, the individual modules 12-50 in the communication network 68 are equal participants and have the same access rights. Each participant can hear and speak in the communication network 68 and can receive and send data via the communication network 68. Inquiries submitted to the communication network 68 can thus, for example, be answered directly. Preferably, the respective communication partners find each other independently. Data exchange can preferably take place in a manufacturer-specific language.

[0155] The various modules 12-50 can be connected to one another and to the central data source 72 via the communication links 70. The communication links 70 can be implemented as wireless and / or wired connections. The modules 12-50 and the central data source 72 can exchange information in the form of data via the communication links 70. The modules 12-50 and the central data source 72 can each send and receive data via the communication links 70. The central data source 72 can, as already mentioned, be part of the control system of the respective container treatment plant. The central data source 72 can preferably be designed as a data storage platform without its own control logic component or the like. It is possible for the central data source 72 to communicate via a communication interface, for example, with a cloud or a server of the manufacturer of the respective container treatment plant.

[0156] Different data can be stored in the central data source 72. The data can be stored in a so-called data table or in another way. The data can be divided into several categories, for example, variety- or product-specific data, production-specific data, and plant or line data.

[0157] The type-dependent data may be data relating to the product to be treated or manufactured, e.g., container size, preform material, filling material / medium to be filled, etc.

[0158] Production-dependent data, on the other hand, may contain information that is not tied to the product(s) and is used for production planning and coordination, such as production output, ambient temperatures, etc.

[0159] The variety-specific and production-specific data can essentially be received or entered externally, e.g., via the cloud, by the commissioning engineer, or by the operator. The individual modules 12–50 can query the data for use. Modules 12–50 can also send feedback to the central data source 72 (e.g., learnings).

[0160] Modules 12–50 can store information in the system data. This information can preferably be information that relates to the entire system, i.e., the respective container handling system, such as fault information, product order information, or profiles of the individual modules 12–50.

[0161] Data is preferably stored in the central data source 72 using a standard form. This ensures that the relevant data is always stored in the same location and can be accessed from there. Modules 12–50 independently retrieve the data they require for production and network interaction. Should an update occur during production or relevant data become available, modules 12–50 can also independently query this information from the central data source 72. Higher-priority data requiring immediate action, such as a fault or emergency stop, can be sent to modules 12–50 as a (push) notification.

[0162] Ideally, all necessary master data required for task processing can be stored in the respective module that can perform the task. This data can contain, for example, information about capabilities, reactions, maintenance intervals, etc. This data can be unique for each variant of modules 12-50, e.g., the type of filler / filling process, and can be transferred to the module before delivery of the respective module 12-50. It is also possible to update or modify this data via the cloud or a manufacturer's server.

[0163] Preferably, modules 12-50 can also make prioritized method calls, such as in the event of a fault, whereupon direct feedback must be sent to a specific participant in the communication network 68. As already mentioned, these messages can be sent to the corresponding participants via (push) notifications so that they can react immediately.

[0164] Another data type of the modules 12 - 50 can be cooperation data, which the respective module 12 - 50 continuously transmits to the communication network 68 during production.

[0165] Preferably, predefined communication protocols and method calls, in which the relevant parameters can be stored in an orderly manner before transmission, can simplify data exchange. The type-specific and production-specific data can be retrieved module-specifically from modules 12 - 50 during initialization of the respective container handling system and temporarily stored until updated or overwritten.

[0166] Fault information regarding an excessive scrap rate can preferably be forwarded directly to the respective module 12-50, which can counteract the detected deterioration, until a critical scrap rate is exceeded. Only if the problem cannot be resolved in this way can global fault information be transmitted to the communication network 68.

[0167] The container processing systems 58, 62, and 66 described herein as examples are suitable, for example, for the flexible production of a wide variety of products in the low to medium output range. Thus, requirements such as a system adjacent to or as part of a supermarket, or a system for products with different versions, labeling, closures, etc., can be very well met with the concept, even though the variety of variants in all product properties is large and fluctuating demand across seasons and production years may be difficult to plan. Furthermore, the option of autonomous modular operation and the corresponding interfaces allow functional units to be used in various peripherals, from stand-alone to cycle-machine operation to high-performance operation with a continuous container flow.Examples of such universally applicable functional modules would be autonomous filling valves, internal coating stations, labeling units, printing technology units, etc. The concept presented can preferably offer a flexible, technologically advanced, and future-proof solution for all requirement profiles.

[0168] The invention is not limited to the preferred embodiments described above. Rather, a multitude of variants and modifications are possible which also make use of the inventive concept and therefore fall within the scope of protection. In particular, the invention also claims protection for the subject matter and features of the subclaims, independent of the referenced claims. In particular, the individual features of independent claim 1 are each disclosed independently of one another. In addition, the features of the subclaims are also disclosed independently of all features of independent claim 1 and, for example, independently of the features relating to the presence and / or configuration of the main conveyor module, the multiple submodule interfaces, the multiple container handling submodules and / or the control system of independent claim 1.

[0169] List of reference symbols

[0170] 10 modular building block system

[0171] 12-16 main conveyor modules

[0172] 18-22 Container treatment main modules

[0173] 24-44 container treatment submodules

[0174] 46-50 conveyor submodules

[0175] 51 Main module interface

[0176] 52 Submodule interface

[0177] 54 Parking Station

[0178] 56 driverless transport vehicles

[0179] 58 Container treatment plant

[0180] 60 preform feeder

[0181] 62 Container treatment plant

[0182] 64 Preform heating device

[0183] 66 Container treatment plant

[0184] 68 Communication network

[0185] 70 communication connections

[0186] 72 central data source

[0187] 74 packing module

Claims

REQUIREMENTS 1. Modular container handling system (58, 62, 66) comprising: a main conveying module (12, 14, 16) arranged for conveying containers through the modular container handling system (58, 62, 66); several sub-module interfaces (52); several container handling sub-modules (24 - 44) that can be coupled to and uncoupled from the several sub-module interfaces (52), preferably automatically by means of an automated guided vehicle (AGV) (56); and a control system that is self-configuring to automatically adapt the operation of the modular tank treatment plant (58, 62, 66) depending on the coupling of at least one of the several tank treatment submodules (24 - 44) to at least one of the several submodule interfaces (52) and / or the disconnection of at least one of the several tank treatment submodules (24 - 44) from at least one of the several submodule interfaces (52).

2. Modular container handling system (58, 62, 66) according to claim 1, further comprising: several container handling main modules (18, 20, 22) that can be coupled to and uncoupled from several main module interfaces (51) of the conveying main module (12, 14, 16), preferably automatically by means of an automated guided vehicle (AGV) (56), wherein the several container handling main modules (18, 20, 22) each comprise: at least one of the several sub-module interfaces (52); and a conveying sub-module (46, 48, 50) that is connected or connectable to the conveying main module (12, 14, 16) for taking the containers from the conveying main module (12, 14, 16) and for transferring the containers back to the conveying main module (12, 14, 16);wherein preferably the control system is further configured to automatically adapt the operation of the modular tank treatment plant (58, 62, 66) depending on the coupling of at least one of the several tank treatment main modules (18, 20, 22) to at least one of the several main module interfaces (51) and / or the disconnection of at least one of the several tank treatment main modules (18, 20, 22) from at least one of the several main module interfaces (51). Modular container treatment system (58, 62, 66) according to claim 1 or claim 2, wherein the control system is configured to: receive production order information for treating the containers; and automatically adapt the operation of the modular container treatment system (58, 62, 66) and / or the respective connection and disconnection of the multiple container treatment submodules (24 -- 44) at the multiple submodule interfaces (52) depending on the received production order information.Modular container handling system (58, 62, 66) according to one of the preceding claims, wherein the control system is configured to: generate a movement path of the containers through the modular container handling system (58, 62, 66) during automatic adjustment of operation, including at least some of the multiple container handling submodules (24-44), and to control a movement of the containers according to the generated movement path; and / or to adjust operating parameters of the main conveying module (12, 14, 16) and / or the multiple container handling submodules (24-44) during automatic adjustment of operation; and / or to further automatically adjust the operation and / or the respective coupling and uncoupling depending on experience data in which previous operations of the modular container handling system (58, 62, 66) and / or other container handling systems are stored.Modular container treatment system (58, 62, 66) according to one of the preceding claims, further comprising: a parking station (54); and a driverless transport vehicle (56) for transporting at least one of the multiple container treatment submodules (24 --44) between the parking station (54) and the multiple submodule interfaces (52).

6. Modular container handling system (58, 62, 66) according to claim 5, wherein: the control system is configured to control, depending on received production order information, the transport of at least one of the several container handling sub-modules (24 - 44) between the parking station (54) and at least one of the several sub-module interfaces (52) for coupling or uncoupling the respective container handling sub-module (24 - 44) by means of the driverless transport vehicle (56).

7. Modular container handling system (58, 62, 66) according to claim 2 and claim 5 or 6, wherein: the control system is configured to control, depending on received production order information, the transport of at least one of the several main container handling modules (18, 20, 22) between the parking station (54) and at least one of the several main module interfaces (51) for coupling or uncoupling the respective main container handling module (18, 20, 22) by means of the driverless transport vehicle (56).

8. Modular container handling system (58, 62, 66) according to one of the preceding claims, wherein the control system is configured to generate and / or receive fault information indicating a predicted or actual defect of a component and, depending on fault information: to control an automatic repair or automatic replacement of the component and / or software code associated with the component; and / or to automatically adjust the operation of the modular container handling system (58, 62, 66) such that the component is bypassed by the containers and / or software code associated with the component is bypassed, preferably while the component and / or software code associated with the component is being automatically replaced or repaired; and / or to control an automatic disconnection of the container handling submodule (24-44) that includes the component.

9. Modular container treatment plant (58, 62, 66) according to one of the preceding claims, wherein the multiple container treatment submodules (24 - 44) comprise at least one of: at least one labeling submodule (36) for labeling the containers; at least one testing submodule (38) for testing the containers; at least one printing submodule (34) for printing on the containers; at least one cleaning submodule (40) for cleaning the containers; at least one filling submodule (42) for filling the containers; at least one closing submodule (44) for closing the containers; at least one heating submodule (24) for heating preforms of the containers; at least one forming submodule (26) for forming the containers from preforms, preferably by stretch blow molding; at least one turning submodule (30) for turning the containers over; at least one cooling submodule (28) for cooling the containers; at least one coating submodule (32) for coating the containers; at least one pasteurizing module for pasteurizing the containers; at least one drying module for drying the containers; at least one grouping module for grouping the containers; at least one packaging module for packaging the containers;at least one palletizing module for palletizing the containers; at least one depalletizing module for depalletizing the containers; at least one unpacking module for unpacking the containers; and at least one dating module for dating the containers. Modular container handling system (58, 62, 66) according to claim 2 and claim 9, wherein: at least one testing submodule (38) and at least one labeling submodule (36) and / or printing submodule (34) are included, which are jointly coupled to several submodule interfaces (52) of one of the several container handling main modules (18, 20, 22), preferably to form a container equipment main module (20.4, 20.5, 22.5, 22.6, 18.7); and / or comprises several filling submodules (42) and several closing submodules (44) which are jointly coupled to several submodule interfaces (52) of one of the several container handling main modules (18, 20, 22), preferably to form a container filling and closing main module (20.6, 20.7); and / or; comprising several heating submodules (24) and several forming submodules (26) which are jointly coupled to several submodule interfaces (52) of one of the several container treatment main modules (18, 20, 22), preferably to form a container manufacturing main module (20.1, 20.2).

11. Modular container treatment system (58, 62, 66) according to one of the preceding claims, wherein: the control system comprises several decentralized control units assigned to the main conveying module (12, 14, 16) and / or the several container treatment submodules (24 - 44), and a central data source (72); and the several decentralized control units and the central data source (72) are configured to jointly coordinate the adjustment of the operation of the modular container treatment system (58, 62, 66) when connecting and / or disconnecting one of the several container treatment submodules (24 - 44) for the purpose of self-configuring the control system, wherein preferably type-dependent data, production-dependent data and plant data are stored in the central data source.

12. Modular container treatment system (58, 62, 66) according to one of the preceding claims, wherein: the multiple submodule interfaces (52) each have an electrical connection, a communication connection, a fluid connection and / or a mechanical connection; and / or the multiple submodule interfaces (52) are identical in construction.

13. Modular container handling system (58, 62, 66) according to one of the preceding claims, wherein at least one of the following features is fulfilled: the main conveying module (12, 14, 16) is arranged centrally in the container handling system (58, 62, 66); the main conveying module (12, 14, 16) is designed as a transport carousel, as a long stator or short stator linear drive conveyor, as a planar drive conveyor, as a belt conveyor or as a neck handling conveyor; and the several container handling submodules (24 - 44) are arranged distributed around the main conveying module (12, 14, 16). Method for manufacturing a modular container treatment plant (58, 62, 66), preferably according to one of the preceding claims, by means of a modular construction system (10), comprising: Selecting a conveying main module (12, 14, 16) from several different conveying main modules (12, 14, 16) of the modular system (10), preferably by means of a graphical user interface, wherein: the several different conveying main modules (12, 14, 16) can each be arranged for conveying containers through the modular container handling system (58, 62, 66); and the several different conveying main modules (12, 14, 16) each have several main module interfaces (51); Selecting several container treatment main modules (18, 20, 22) from a plurality of different container treatment main modules (18, 20, 22) of the modular system (10), preferably by means of the graphical user interface, wherein: the plurality of different container treatment main modules (18, 20, 22) can be connected to the multiple main module interfaces (51); the plurality of different container treatment main modules (18, 20, 22) each have multiple sub-module interfaces (52); and the multitude of different container handling main modules (18, 20, 22) each have a conveying sub-module (46, 48, 50) that can be connected to the selected conveying main module (12, 14, 16) for taking the containers from the selected conveying main module (12, 14, 16) and for transferring the containers back to the selected conveying main module (12, 14, 16); Selecting several container treatment submodules (24 - 44) from a plurality of different container treatment submodules (24 - 44) of the modular system (10), preferably by means of the graphical user interface, wherein: the plurality of different container treatment submodules (24 - 44) can be coupled to the multiple submodule interfaces (52); Assembling the modular tank treatment plant (58, 62, 66) from the selected main conveying module (12, 14, 16), the selected main tank treatment modules (18, 20, 22) and the selected tank treatment sub-modules (24 - 44). Method for operating a modular tank treatment plant (58, 62, 66) according to one of claims 1 to 13, comprising: automatic adaptation of the operation of the modular tank treatment plant by means of self-configuration of the control system depending on the coupling and / or disconnection of at least one of the several tank treatment submodules (24) -- 44); and optionally automatic adjustment of the operation of the modular tank treatment plant by means of self-configuration of the control system depending on the coupling and / or decoupling of at least one of the several main tank treatment modules (18 - 22).

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