Method and system for setting up an automatic machine prototype and use of such a machine
Patent Information
- Application Number
- EP2023739681
- Authority / Receiving Office
- EP · EP
- Patent Type
- Applications
- Current Assignee / Owner
- Priority Date
- 2022-07-01
- Filing Date
- 2023-06-27
- Publication Date
- 2025-05-07
AI Technical Summary
Complex automatic machines, such as those producing smoking articles, face inefficiencies and prolonged setup times due to the inability to effectively test prototypes until commissioning at the customer's facility, leading to costly redesigns and delays, as well as the need for rapid component manufacturing and reduced lead times.
A method and system utilizing a 3D printer at the production site to rapidly manufacture new components based on digital engineering drawings created remotely, allowing for immediate replacement of malfunctioning parts and optimizing machine operation, with the 3D printer located within a short distance from the production site to minimize setup time and costs.
This approach significantly reduces setup time and costs by enabling on-site production of necessary components, allowing for quick resolution of malfunctions and optimizing machine operation without the need for extensive redesign or material transportation, thereby streamlining the commissioning process.
Smart Images
Figure 1.1
Abstract
Description
[0001] DESCRIPTION
[0002] METHOD AND SYSTEM FOR SETTING UP AN AUTOMATIC MACHINE PROTOTYPE AND USE OF SUCH A MACHINE
[0003] Technical field
[0004] This invention relates to a method and a system for setting up an automatic machine prototype and to a use of such a machine.
[0005] Background art
[0006] In the field of particularly complex automatic machines, there is a strongly felt need for being able to optimize the process of commissioning a machine prototype constructed according to a customer's specifications and requirements. In most cases, complex automatic machines such as those for producing smoking articles, like cigarettes, for example, are designed using, to some extent, modules already used for other machines and modules constructed to the customer's specifications.
[0007] Generally speaking, most of these machines are subsequently linked up in lines or installations already in existence at one of the customer's production facilities.
[0008] In this sense, the constructor of such machines is unable to effectively test the automatic machine prototype until commissioning takes place at the customer's production facility.
[0009] In most cases, malfunctioning or non-optimum operation of the machine prototype occurs, which means some of the components of the machine need to be redesigned or modified to set the problem right.
[0010] Normally, therefore, the constructor makes a new component for the machine prototype at their own production facility and sends the component to the customer's production facility so it can be installed on the automatic machine prototype to fix the problem.
[0011] This procedure is far from being ideal and gives rise to numerous costs and inefficiencies, in addition to increasing lead times and making the process for setting up the machine particularly long and complex. It should be noted that there is also a long-standing need to also shorten the time scale for manufacturing the components of a machine prototype; in effect, the manufacturing materials are not always available at the machine constructor's facility and this may contribute to increasing the time needed for setting up.
[0012] In this context, there is a particularly strongly felt need for setting up an automatic machine prototype quickly and easily, with a short time scale and at a reduced cost.
[0013] Disclosure of the invention
[0014] This invention therefore has for an aim to provide a method and a system for setting up an automatic machine prototype to meet the above mentioned need.
[0015] More precisely, the aim of this invention is to provide a method and a system for setting up an automatic machine prototype.
[0016] Brief description of the drawings
[0017] The technical features of the invention, with reference to the above aims, are clearly described in the annexed claims and its advantages are more apparent from the detailed description which follows, with reference to the accompanying drawing which illustrates a non-limiting embodiment of the invention and in which:
[0018] - Figure 1 is a schematic representation of a first embodiment of a system according to the invention.
[0019] Detailed description of preferred embodiments of the invention
[0020] Defined according to this invention is a method for setting up an automatic machine 1 prototype, comprising the following steps:
[0021] - providing an automatic machine 1 prototype at a production site 2;
[0022] - starting the automatic machine 1 prototype at the production site 2;
[0023] - identifying a malfunction of at least one malfunctioning component 3A of the automatic machine 1 prototype;
[0024] - making, at a design site 4 situated at a geographical location different from that of the production site 2 (that is, situated at some distance from the production site 2), using a graphic design computer 5, a digital engineering drawing 11 of at least one new component 3B to replace the malfunctioning component 3a of the automatic machine 1 prototype;
[0025] - deriving, from the digital engineering drawing 11 , programming instructions for a 3D printer 6 configured to allow the new component to be made on the 3D printer 6;
[0026] - sending the programming instructions to the 3D printer 6 to print the new component 3B with the 3D printer 6 by deposition of superposed layers of material;
[0027] - mounting the new component 3B on the automatic machine 1 prototype in place of the malfunctioning component 3A;
[0028] - starting the automatic machine 1 prototype at the production site 2 to check the functioning of the automatic machine 1 prototype with the new component 3B mounted. It should be noted that the expression "situated at a geographical location different from" is used to mean that the production site 2 is located at a distance from the design site 4 greater than a certain value (preferably greater than 100 km, and still more preferably, greater than 1000 km).
[0029] It should also be noted that the greater the distance between the production site 2 and the design site 4, the greater the advantages of the proposed method, in particular in terms of the setting up time scale.
[0030] The term "digital engineering drawing" is used to mean any file containing the geometries of the new component 3B. The "digital engineering drawing" can be made using any graphic design or CAD software.
[0031] The expression "defective component" is used generically to denote a component of the automatic machine 1 that generates or causes non- optimal (or suboptimal) functioning of the automatic machine 1. In other words, the expression "defective component" is used to denote a malfunctioning component in the sense that it generates or causes nonoptimum (or suboptimum) operation of the automatic machine 1 .
[0032] It should also be noted that the automatic machine 1 prototype may be a machine of any kind.
[0033] The new component 3B may be a component of any kind, such as, by way of non-limiting example, a packaging machine (in particular, for tobacco articles), more specifically, for example, a component for folding the panels of blanks, an opposing element for packets of tobacco articles, a positioning element for blanks, a support for at least one sensor.
[0034] The step of identifying a malfunction of at least one malfunctioning component 3A of the automatic machine 1 prototype may comprise a step of identifying a non-optimum (or suboptimum) operation of the machine, that is, operation that leads to defects, production slowdowns, scrap products, etc.
[0035] Preferably, but not necessarily, the automatic machine 1 prototype is designed to make a product of any kind (preferably a smoking article or a part of a smoking article).
[0036] According to another aspect, the automatic machine 1 prototype may be a machine for packaging a product (or a group of products).
[0037] According to another aspect, the method comprises the following steps:
[0038] - providing a remote computer 7, connected to the 3D printer 6 to drive it;
[0039] - providing a receiving module 8 for receiving data in the remote computer 7;
[0040] - providing a data transmission module 9 in the graphic design computer 5, configured to transmit data, relating to the programming instructions, to the receiving module 8.
[0041] It should be noted that the remote computer 7 may be any computer, whether external or integrated in the 3D printer 6.
[0042] The 3D printer 6 may be any three-dimensional printer configured to make any three-dimensional component or object by the addition of material (additive method). The 3D printer 6 may be configured to fuse or weld or heat the additive material defining the three-dimensional component or object.
[0043] The 3D printer 6 is therefore provided with means for heating the additive material.
[0044] The data receiving module 8 is a hardware and / or software module.
[0045] The data receiving module 9 is a hardware and / or software module.
[0046] According to another aspect, the method comprises the step of positioning the 3D printer 6 at or in the vicinity of the production site 2.
[0047] The preposition "at" indicates the exact position or physical location mentioned, that is to say, the production site 2.
[0048] The expression "in the vicinity of", on the other hand, indicates a place near the physical location mentioned, that is to say, near the production site 2.
[0049] In short, according to an aspect, the 3D printer 6 is preferably located at or near the production site 2.
[0050] Preferably, the 3D printer is located in the vicinity of the production site 2, at a distance less than or equal to 150 km from the production site 2.
[0051] Still more preferably, the 3D printer is located in the vicinity of the production site 2, at a distance less than or equal to 100 km from the production site 2.
[0052] Advantageously, this allows the new component 3B to be made directly at the production site 2, saving a considerable amount of time in setting up the machine 1 .
[0053] According to another aspect, the method also comprises a step of providing a sensor 9 in the automatic machine 1 prototype at the production site 2, configured to detect least one operating parameter of the automatic machine 1 prototype.
[0054] It should be noted that the sensor 9 may be a sensor of any kind: a sensor for detecting force, current, voltage, pressure, distance, temperature, colour, shape, etc.
[0055] The step of identifying a malfunction of at least one malfunctioning component 3A of the automatic machine 1 prototype comprises a step of detecting the operating parameter of the automatic machine 1 (through the sensor 9) and deriving a malfunction or non-optimum (or suboptimum) operation of the automatic machine 1 prototype as a function of the operating parameter detected.
[0056] According to another aspect, the step of sending the programming instructions to the 3D printer 6 to print the new component 3B with the 3D printer 6 comprises a step of sending transmission data in encrypted form. It should therefore be noted that, advantageously, the printing process cannot, unless specifically authorized, be replicated by decrypting the printing instructions.
[0057] According to another aspect, the method comprises a step of sending programming instructions directly to the 3D printer 6 through a further computer at the production site so as to print the new component 3B with the 3D printer 6 by deposition of superposed layers of material.
[0058] In such a case, therefore, the method does not include the step of making the digital engineering drawing 11 of the new component 3B at the design site 4 and deriving, from the digital engineering drawing 11 , the programming instructions for the 3D printer. In effect, in this case, the programming instructions for the 3D printer are ready at the production site.
[0059] Preferably, the new component 3B is a spare part.
[0060] More precisely, an operator at the production site sends the programming instructions to the 3D printer 6, already in their possession, to print the new component 3B to replace the malfunctioning component 3A of the automatic machine 1 prototype.
[0061] That way, it is possible to take direct action on site (that is, at the production site, where the automatic machine 1 is located) using programming instructions already present there to make components with the 3D printer 6, thereby further reducing the time needed for the process for setting up the automatic machine 1 . According to another aspect, the invention defines a system 100 for setting up an automatic machine 1 prototype, comprising:
[0062] - an automatic machine 1 prototype located at a production site 2 and comprising at least one sensor 9 configured to detect an operating parameter of the automatic machine 1 prototype, usable to identify a malfunctioning component 3A;
[0063] - a 3D printer (6);
[0064] - a remote computer 7 connected to the 3D printer 6 to drive it and comprising a data receiving module 8 configured to receive programming instructions for a 3D printer 6 to allow driving the 3D printer 6 through the programming instructions and making a new component 3B for the automatic machine 1 prototype on the 3D printer 6 by deposition of superposed layers of material.
[0065] The new component 3B is used to replace the malfunctioning component 3A.
[0066] The malfunctioning component 3A is the cause of non-optimum (or suboptimum) operation of the machine 1 , or leads to defects, production slowdowns, etc.
[0067] According to another aspect, the system 100 further comprises a graphic design computer 5, provided with a data transmission module 9 configured to transmit the programming instructions to the data receiving module 8.
[0068] The graphic design computer 5 may be a computer of any kind, a PC, a processor, etc.
[0069] According to yet another aspect, the 3D printer 6 and the remote computer 7 are located at or in the vicinity of the production site 2.
[0070] Preferably, the 3D printer and the remote computer 7 are located in the vicinity of the production site 2, at a distance less than or equal to 150 km from the production site 2.
[0071] Still more preferably, the 3D printer and the remote computer 7 are located in the vicinity of the production site 2, at a distance less than or equal to 100 km from the production site 2. According to yet another aspect, the graphic design computer 5 is located at a design site 4.
[0072] Advantageously, the system 100 and the method described allow greatly reducing the time needed for setting up the automatic machine 1 prototype. In effect, in the event of malfunctions or non-optimum operation of the automatic machine 1 prototype, it is possible to replace the malfunctioning component 3A (that is, the one causing the sub-optimum operation) with a new component 3B made at or in the vicinity of the same production site 2 where the machine 1 is located.
[0073] That way, the lead time for supplying the new component 3B can be very greatly reduced since it can be made directly at or in the vicinity of the production site 2.
[0074] Advantageously, therefore, the design site 4 where the new component 3B can be designed can be kept separate from the production site 2, thus facilitating the setting up of the automatic machine 1 prototype.
[0075] The new component 3B is designed where the designers are, that is to say, at the design site 4, while it is physically made on the production site 2 (at or in the vicinity of the production site 2).
[0076] It should be noted that, according to the invention, the new component 3B is produced in the vicinity of the automatic machine 1 prototype, with considerable advantages in terms of time scale and costs.
[0077] Also defined according to this disclosure, is a use of an automatic machine 1 prototype at a production site 2, where the automatic machine 1 prototype comprises at least one sensor 9 configured to detect at least one operating parameter of the automatic machine 1 prototype usable to identify a malfunctioning component 3A, wherein:
[0078] - during operation of the machine, an engineer, through the sensor 9, identifies a non-optimum operation due to a malfunctioning component 3A;
[0079] - the engineer sends to a design site 4 a remote request to rectify the non- optimum operation in order to receive instructions for printing a new component 3B adapted to rectify the non-optimum operation; - the engineer prints the new component 3B on a 3D printer 6 by deposition of superposed layers of material;
[0080] - the engineer replaces the malfunctioning component 3A in the automatic machine 1 prototype with the new component 3B so as to rectify the non- optimum operation.
[0081] It should be noted that the term "engineer" is used broadly to mean operating personnel, that is to say, either a user or a maintenance technician.
[0082] The use of the automatic machine 1 prototype may further comprise the following steps:
[0083] - making, at a design site 4 situated at a geographical location different from that of the production site 2, using a graphic design computer 5, a digital engineering drawing 11 of at least one new component 3B to replace the malfunctioning component 3a of the automatic machine 1 prototype;
[0084] - deriving, from the digital engineering drawing 11 , programming instructions for a 3D printer 6 configured to allow the new component 3B to be made on the 3D printer 6.
Claims
CLAIMS1) A method for setting up an automatic machine (1 ) prototype, comprising the following steps:- providing an automatic machine (1 ) prototype at a production site (2);- starting the automatic machine (1 ) prototype at the production site (2);- identifying a malfunction or a non-optimum operation of at least one component (3A) of the automatic machine (1 ) prototype;- making, at a design site (4) situated at geographical location different from the production site (2), in particular using a graphic design computer (5), a digital engineering drawing (11 ) of at least one new component (3B) to replace the malfunctioning component (3a) of the automatic machine (1 ) prototype;- deriving, from the digital engineering drawing (11 ), programming instructions for a 3D printer (6) configured to allow the new component (3B) to be made on the 3D printer (6);- sending the programming instructions to the 3D printer (6) to print the new component (3B) with the 3D printer (6) by deposition of superposed layers of material;- mounting the new component (3B) on the automatic machine (1 ) prototype in place of the malfunctioning component (3A);- starting the automatic machine (1 ) prototype at the production site (2) to check the functioning of the automatic machine (1 ) prototype with the new component (3B) mounted.2) The method according to the preceding claim, comprising the following steps:- providing a remote computer (7), connected to the 3D printer (6) to drive it;- providing a receiving module (8) for receiving data in the remote computer (7);- providing a data transmission module (9) in the graphic design computer(5), configured to transmit data, relating to the programming instructions, to the receiving module (8).3) The method according to either of the preceding claims, further comprising a step of positioning the 3D printer (6) at or in the vicinity of the production site (2).4) The method according to any one of the preceding claims, further comprising the step of providing a sensor (9) in the automatic machine (1 ) prototype at the production site (2), configured to detect least one operating parameter of the automatic machine (1 ) and wherein the step of identifying a malfunction of at least one malfunctioning component (3A) of the automatic machine (1 ) prototype comprises a step of detecting the operating parameter of the automatic machine (1 ) and deriving a malfunction or non-optimum operation of the automatic machine (1 ) prototype as a function of the operating parameter detected.5) The method according to any one of the preceding claims, wherein the step of sending the programming instructions to the 3D printer (6) to print the new component (3B) with the 3D printer (6) comprises a step of sending transmission data in encrypted form.6) The method according to any one of the preceding claims, comprising a step of sending programming instructions directly to the 3D printer (6) through a further computer located at the production site so as to print the new component (3B) with the 3D printer (6) by deposition of superposed layers of material.7) A system (100) for setting up an automatic machine (1 ) prototype, comprising:- an automatic machine (1 ) prototype located at a production site (2) andcomprising at least one sensor (9) configured to detect an operating parameter of the automatic machine (1 ) prototype, usable to identify a malfunctioning component (3A);- a 3D printer (6);- a remote computer (7) connected to the 3D printer (6) to drive it and comprising a data receiving module (8) configured to receive programming instructions for a 3D printer (6) to allow driving the 3D printer (6) through the programming instructions and making a new component (3B) for the automatic machine (1) prototype on the 3D printer (6) by deposition of superposed layers of material.8) The system (100) according to claim 7, further comprising a graphic design computer (5), provided with a data transmission module (9) configured to transmit the programming instructions to the data receiving module (8).9) The system (100) according to claim 7 or 8, wherein the 3D printer (6) and the remote computer (7) are located at or in the vicinity of the production site (2).10) The system (100) according to any one of claims 7 to 9 and claim 8, wherein the graphic design computer (5) is located at a design site (4).11) A use of an automatic machine (1 ) prototype at a production site (2), where the automatic machine (1 ) prototype comprises at least one sensor (9) configured to detect least one operating parameter of the automatic machine (1 ) prototype usable to identify a malfunctioning component (3A), wherein:- during operation of the automatic machine (1 ) prototype, an engineer, through the sensor (9), identifies a non-optimum operation due to a malfunctioning component (3A);- the engineer sends to a design site (4) a remote request to rectify the non-optimum operation in order to receive instructions for printing a new component (3B) adapted to rectify the non-optimum operation;- the engineer prints the new component (3B) on a 3D printer (6) by deposition of superposed layers of material;- the engineer replaces the malfunctioning component (3A) in the automatic machine (1 ) prototype with the new component (3B) so as to rectify the non-optimum operation.12) The use according to claim 11 , wherein, the engineer, if already in possession of the instructions for printing the new component (3B) to rectify the non-optimum operation, proceeds directly to printing the new component (3B) on the 3D printer (6) by deposition of superposed layers of material without sending to the design site (4) the remote request to rectify the non-optimum operation.