Method for guiding a user when changing a process, computer-program product and system

Abstract

The invention relates to a method (100) for guiding a user when changing a process from a production process (200) for producing a first film material (201) to a subsequent process (210) for producing a second film material (211) in an extrusion device (10). The invention also relates to a computer-program product and to a system (1).

Description

[0001] Method for user guidance for a process change, computer program product and system

[0002] Description

[0003] The invention relates to a method for user guidance for a process change in an extrusion device, a computer program product and a system for user guidance for a process change.

[0004] It is generally known that extrusion devices in the form of film machines can produce a variety of products. These products typically differ from one another due to different recipes. Thus, a series of different orders with different recipes are processed sequentially. To transition between two recipes, a switch is made from a currently used recipe to a subsequent one. In existing solutions, this switch is usually performed manually and based on the experience of the machine operator.

[0005] The disadvantage of such solutions is that the quality and, above all, the time required to perform the changeover from one recipe to the subsequent recipe are based solely on the machine operator's knowledge. This can result in a very high scrap rate for this changeover between recipes, especially for inexperienced machine operators. In particular, a clear and consistent quality requirement for all changes to subsequent recipes cannot be achieved in this way. Last but not least, the possibility of errors cannot be ruled out.

[0006] Therefore, it is known from DE 10 2015 108 972 A1 to guide a machine operator step by step during a recipe change. This avoids incorrect strategies or incorrect sequences of individual changeover steps during the recipe change, especially for a machine operator with little experience, and significantly reduces the risk of such incorrect assignment. However, it is desirable to provide meaningful support to both inexperienced and experienced machine operators during a process change.

[0007] It is an object of the present invention to at least partially remedy the above-mentioned disadvantages known from the prior art. In particular, it is an object of the present invention to enable improved user guidance for a process change of an extrusion device, which preferably provides a machine operator with an overview of the ongoing manufacturing process and simultaneously simplifies the process change.

[0008] The above object is achieved by a method having the features of claim 1, a computer program product having the features of claim 17, and a system having the features of claim 18. Further features and details of the invention emerge from the respective subclaims, the description, and the drawings. Features and details described in connection with the method according to the invention naturally also apply in connection with the computer program product according to the invention and / or the system according to the invention, and vice versa, so that with regard to the disclosure of the individual aspects of the invention, reciprocal reference is or can always be made.

[0009] According to a first aspect of the invention, a method for user guidance for a process change from a manufacturing process for producing a first film material to a subsequent process for producing a second film material in an extrusion device is provided. The method comprises, in particular in the form of method steps:

[0010] - Recording a set of process parameters of the manufacturing process for producing the first film material, in particular by a control system and / or a sensor system of the extrusion device,

[0011] - Determining a target subsequent parameter set of the subsequent process assigned to the process parameter set, in particular by retrieving the process parameter set from a memory unit of the control system, Determining comparison data of a comparison of the process parameter set with the target subsequent parameter set in order to detect deviations of the target subsequent parameter set from the process parameter set, in particular by the control system,

[0012] - Output of display data for the joint display of several comparison elements to show the deviations based on the comparison data during the manufacturing process, in particular by the control system, detection of a user interaction for controlling the extrusion device for at least partial or complete adaptation of the process parameter set, in particular by the control system,

[0013] - Updating the display data, in particular the comparison elements, depending on the adaptation of the process parameter set, preferably during the manufacturing process, in particular by the control system.

[0014] The extrusion device can advantageously be a film machine, in particular a cast film machine and / or a blown film machine. The extrusion device can comprise one or more extruders for heating, mixing, and / or conveying raw material.

[0015] Preferably, the first and second film materials are each formed as plastic films. The first film material and the second film material can preferably differ in a recipe, i.e. in particular a material composition, and / or in a format. For example, different raw materials and / or different proportions of raw materials can be used for the first and second film materials. The format can preferably be understood to mean a geometric configuration, such as a film width and / or film thickness, of the first and second film materials. A production result of the manufacturing process can comprise a first film product, e.g. a tubular and / or flat film, and a production result of the subsequent process can comprise a second film product, e.g. a tubular and / or flat film.The first and second film products can each be manufactured and / or processed in individual film sections or contiguously. It can be provided that a type of process change is detected by determining whether the process change includes a format and / or a material change. The display data and / or the comparison elements can be determined depending on the type of process change, in particular to provide adapted operating pages.

[0016] The manufacturing process and the subsequent process can each comprise a manufacturing order. In this case, the process change can preferably take place without stopping the extrusion device, so that the manufacturing process and the subsequent process merge into one another and / or film material is continuously produced. The manufacturing process is understood in particular to mean good production of the first film material, i.e. production of the first film material which satisfies at least one quality criterion for the first film material, in particular for the sale of the first film material. The subsequent process is understood in particular to mean good production of the second film material, i.e. production of the second film material which satisfies at least one quality criterion for the second film material, in particular for the sale of the second film material.A changeover process can be carried out between the manufacturing process and the subsequent process, in which only scrap material is produced that neither meets the quality criteria for the first film material nor the quality criteria for the second film material. The changeover process is preferably minimized by the method according to the invention.

[0017] The process parameter set can comprise one or more process parameters of actual machine data and / or target machine data of the extrusion device, in particular in the form of sensor data and / or control and / or regulation data, for the manufacturing process. For example, the process parameter set can comprise temperature data of the extrusion device and / or material conveying data of the extrusion device, in particular in the form of a conveying speed and / or an extruder rotational speed. It can be provided that the process parameter set is recorded and preferably updated continuously or discontinuously, in particular during the manufacturing process. The process parameter set is preferably recorded in real time during the manufacturing process.

[0018] The target subsequent parameter set can comprise one or more target subsequent parameters of target machine data of the extrusion device, in particular in the form of control and / or regulation data, for the subsequent process. In particular, the target subsequent parameter set can comprise temperature data of the extrusion device and / or material conveying data of the extrusion device, in particular in the form of a conveying speed and / or an extruder rotational speed. Thus, the target subsequent parameter set can comprise one or more target subsequent parameters that are assigned to the one or more process parameters of the process parameter set, but relate to the subsequent process. When determining the target subsequent parameter set, the target subsequent parameter set can be retrieved, for example, from a storage unit and / or from a database. However, it is also conceivable for the target subsequent parameter set to be acquired by user input, in particular on the extrusion device.

[0019] To determine the comparison data, for example, a difference between the target subsequent parameters and the process parameters can be calculated. The comparison elements can advantageously comprise a qualitative and / or quantitative representation of the comparison data. For example, the comparison elements can comprise a display of a value of the difference between the target subsequent parameters and the process parameters. However, it is also conceivable for the deviations from the comparison data to be represented in color in the display data by the comparison elements. The joint display of the comparison elements can be understood as a simultaneous display of several deviations, in particular in one view. In this case, the display data can comprise a user interface in which the comparison elements with the deviations are integrated, in particular graphically. When outputting the display data, the display data can, for example,be displayed on a display device or sent to a display device. It is conceivable that the output of the display data comprises a display of the display data directly on the extrusion device and / or a display at a control center. When the display data is updated, the display data can be output again. The display data can further comprise additional information, such as order data and / or recipe data for the first and / or second film material.

[0020] It can be provided that the extrusion device is controlled manually and / or actively, in particular electronically, depending on the user interaction. The user interaction can be detected by detecting a user input, in particular on the extrusion device. For example, the user interaction can comprise a control action and / or data communication for controlling the extrusion device. Furthermore, the user interaction can be detected by detecting a confirmation of the execution of the user interaction, in particular on the display device. The adaptation of the process parameter set can comprise an at least partial or complete adjustment of one or more, preferably all, process parameters of the process parameter set to the respectively assigned target subsequent parameters of the target subsequent parameter set.In particular, the recording of user interaction and / or the updating of the display data can be carried out continuously or discontinuously in a repetitive manner.

[0021] The method therefore particularly comprises dynamic process control for the interaction of a user with the extrusion device during the ongoing manufacturing process in order to prepare for the subsequent process. This makes it possible to shorten a process change, particularly with regard to changeover time and / or material consumption. By displaying the comparison elements together during the manufacturing process, both experienced and inexperienced users can obtain a comprehensive overview of the current process parameter set as well as the adjustments to be made for the subsequent process. With user interaction, it can be up to the user to decide which adjustments they make based on the display data that can be identified from the comparison data. It can be provided that the display data, in particular the comparison elements, include a comment on the deviations. This allows less experienced users, for example, tomay be guided more by the display data than experienced users. At the same time, the output of display data during the manufacturing process also provides an overview of the currently running manufacturing process, so that process reliability can be ensured until the process change and / or the manufacturing process itself is completed. By updating the display data, a constant check can be carried out to determine whether the current adjustments meet the requirements of the manufacturing process and / or the subsequent process. This allows incorrect operation and / or disadvantageous operating actions to be detected and a counter-reaction to be made. Furthermore, a user can see at any time how the user interaction affects other process parameters, allowing subsequent user interactions to be adjusted accordingly.Through the preparatory measures for the process change, the process change can be at least partially shifted into the manufacturing process, thereby preferably blurring the boundary between the manufacturing process and the subsequent process. Furthermore, in a method according to the invention, it can advantageously be provided that the process parameter set and / or the comparison elements comprise material data from material ingredients and / or sensor data from sensors of the extrusion device. The sensor data can, for example, comprise motor current values ​​of an electric motor, temperature values ​​and / or a temperature profile on a component of the extrusion device and / or the like. The sensor data thus particularly comprises actual process parameters that can be compared with target subsequent parameters for the subsequent process. Based on this, it can be determined at any time how far the process change has been implemented on the extrusion device.Furthermore, the sensor data can include image data, in particular for detecting a bubble shape. The material data can include, for example, a material type, a material composition, in particular with percentages of the material ingredients, and / or material properties, such as a viscosity of the material ingredients. The material ingredients can be understood to mean, in particular, raw materials of the manufacturing process. When comparing the process parameter set with the target subsequent parameter set, a comparison of the material data for the manufacturing process and the subsequent process can be used to determine, for example, a rinsing preparation and / or a required temperature adjustment for the subsequent process. This can facilitate a material change of a raw material from the manufacturing process to the subsequent process.

[0022] It is further conceivable in a method according to the invention that the method comprises the following step:

[0023] Determining at least one recommended action for adapting the process parameter set, preferably during the manufacturing process, for the subsequent process as a function of the comparison data, in particular wherein the recommended action is output with the preferably updated display data, in particular by the control system and / or a display device. The recommended action can be integrated into the display data and / or can be displayed in addition to the display data. It is conceivable for the recommended action to be designed as a comment in the display data. For example, the recommended action can be in text form or by highlighting in the display data. For example, control fields, such as buttons, can be highlighted in the display data for the recommended action. Furthermore, the recommended action can be output before and / or after user interaction.In particular, when determining the recommended action, an evaluation of the user interaction can be carried out depending on a process condition of the manufacturing process and / or the subsequent process. The process condition can comprise a quality criterion of the first and / or second film material and / or a process stability criterion. The recommended action can therefore enable improved interaction between an operator and the manufacturing process in order to execute and / or prepare the process change. It can be provided that the recommended action contains a process warning. In this case, a current configuration of the process parameter set can preferably be retained until the user confirms the process warning, in particular in order to prevent incorrect process control and a possible resulting process interruption.Preferably, the recommended course of action is determined as a function of a target variable, in particular one to be optimized, in particular wherein the target variable comprises a material quantity, a changeover time for the process change, a quality criterion for the first film material and / or the second film material and / or process reliability when carrying out the process change. The material quantity can relate to a material ingredient, ie, in particular a raw material, for the first and / or second film material. However, it is also conceivable for the target variable to comprise a material quantity of a film material produced by the extrusion device, ie, in particular a starting material.

[0024] Furthermore, in a method according to the invention, it can advantageously be provided that the recommended action comprises a manual activity and / or a recommendation for controlling the extrusion device. The recommended action can be understood in particular as an instruction for operating the extrusion device and / or for carrying out a preparatory action. The manual activity can, for example, comprise maintenance work, in particular in the form of cleaning activities and / or emptying at least one filter, on the extrusion device. Furthermore, the manual activity can comprise material procurement. Thus, the user can be instructed with the recommended action to bring a follow-up material from a storage area to the extrusion device or to reconnect a suction lance for supplying the extrusion device with a raw material.The recommended control of the extrusion device can preferably be executed directly via the control system and / or the display device. For example, the comparison data can include links to control commands so that a user can interact directly with the extrusion device and / or the display data.

[0025] Furthermore, in a method according to the invention it can advantageously be provided that the method comprises the following steps:

[0026] Planning at least one process sequence for the manufacturing process and / or the subsequent process as a function of the comparison data, in particular by the control system and / or the display device, in particular wherein the determination of the recommended action takes place as a function of the process sequence and / or a plurality of process sequences. The process sequence can comprise a desired sequence and / or a prediction of a still remaining part of the manufacturing process, in particular at the time of planning the process sequence, and / or the subsequent process. In particular, the process change can be mapped by the process sequence. The process sequence can advantageously be output with the display data. Thus, the process sequence can form a schedule for the operator. Furthermore, based on the process sequence, an influence of the recommended action on the process parameters of the process parameter set can be checked in order to determine the recommended action.In particular, several possible process sequences can be simulated to determine the recommended course of action. This allows complex relationships during the manufacturing process to be identified and an improved recommended course of action to be determined.

[0027] It is further conceivable in a method according to the invention that the process sequence for defining temporal changes comprises a temporal progression of the process parameter set, wherein the output of the display data and / or the determination of the recommended action takes place as a function of the temporal progression. The temporal progression can in particular be used to map a system reaction of the extrusion device as a function of the at least partial adaptation of the process parameter set. For example, the process sequence can comprise an increase in the temperature of a machine component until a target temperature is reached and / or a material consumption until a defined fill level of a storage container and / or a silo is reached. In particular, the temporal progression for each of the process parameters of the process parameter set can be mapped by the process sequence.In particular, time can be defined as a uniform scale for the process parameter set. This also allows different process parameters of the process parameter set to be mapped for process changes, and processes for adapting the process parameter set can be at least partially parallelized and / or chronologically ordered. It is also conceivable that external events, such as a scheduled shift change and / or a maintenance interval for the extrusion device, can be taken into account when planning the process flow when defining the temporal changes.

[0028] Furthermore, in a method according to the invention, it is conceivable that, when determining the recommended action, a plurality of recommended actions are determined to define a sequence of actions, in particular wherein the sequence of actions comprises a chronological order of the recommended actions. Each of the recommended actions can relate to a user interaction required for the process change. The sequence of actions can relate at least partially to the manufacturing process. Furthermore, the sequence of actions can extend beyond the manufacturing process into the subsequent process. The chronological order is preferably determined based on the process flow and / or based on a prioritization of the recommended actions. The prioritization can, for example, be based on the target variable. By prioritizing, it can be avoided, for example, that a user interaction that requires another user interaction in the manufacturing process is carried out first.Furthermore, it is conceivable, for example, that a cost-intensive raw material is added last before the start of the subsequent process in order to minimize or avoid waste of the cost-intensive raw material.

[0029] Within the scope of the invention, it is further conceivable that, in order to define the action sequence, the temporal progression of the process parameter set is taken into account when determining the action recommendations. With the temporal sequence of the action recommendations, the action recommendations can further be integrated into the temporal progression of the process parameter set in order to map the process progression over time. Preferably, several action sequences can be integrated into the process progression one after the other and / or at least partially in parallel. Based on the temporal progression of the process parameter set, the most optimal point in time for outputting the action recommendation with the display data can be determined, particularly with regard to the target variable. It can thus be provided that the action recommendations are output depending on the temporal progression of the process parameter set with the display data, i.e.in particular, each recommended action and / or each sequence of actions is only displayed when the respective recommended action and / or the respective sequence of actions is provided for in the planned process flow. This can simplify the chronological classification of the recommended action for an operator. In particular, it can be provided that the operator only carries out those recommended actions that are already shown to the operator with the display data. It can be provided that a maintenance interval for servicing the extrusion device during the intermediate process is defined for the action sequence. This can prevent dust accumulating during maintenance from affecting good production in the manufacturing process and / or the subsequent process. The action sequence can also include recommended actions beyond the process change.

[0030] Within the scope of the invention, it is further conceivable that the recommended actions for defining the action sequence are divided into groups based on time, in order to allow for time intervals between the groups. In particular, it is conceivable that each action sequence comprises a block of recommended actions to be executed immediately one after the other. Furthermore, it is conceivable that each action sequence and / or each recommended action is assigned a time that the operator requires to execute the respective action sequence and / or recommended action, in particular with an additional tolerance. The time intervals between the groups can be defined in the course of the process.This allows the operator to define block-by-block processing of the recommended actions with respect to the temporal progression of the process parameter set, in order to enable an operator, for example, to operate additional machines in the time intervals between the action sequences.

[0031] Furthermore, in a method according to the invention, it is conceivable that the process flow and / or the action sequence is updated depending on the user interaction, in particular wherein the updating of the display data takes place depending on the updated process flow. The updated process flow and / or the determination of the recommended action can be determined based on a target variable for the manufacturing process, e.g. in the form of a material consumption to be minimized, a process changeover time to be minimized, a quality criterion of the first and / or second film material and / or a process stability criterion. The target variable can be recorded via a user input. By updating the process flow, the recommended actions can be adapted depending on the user interaction.This allows the process flow to be adjusted in the event of unforeseen operator actions and / or unforeseen system reactions of the extrusion device, particularly to enable an improved or optimal process change with regard to the target variable under changed conditions. This allows the operator to be guided through the process change in a navigation-like manner, even from a macroscopic perspective, where every operator action affects the planning of the process flow.

[0032] Furthermore, in a method according to the invention, it can advantageously be provided that, when determining the target subsequent parameter set, parameter sets of several planned manufacturing processes are determined, wherein a prioritization process takes place in which the planned manufacturing processes are compared on the basis of at least one target variable in order to define one of the planned manufacturing processes as the subsequent process. In particular, as with regard to the process sequence, the target variable for the prioritization process can be defined in the form of a material consumption to be minimized, a process changeover time to be minimized, a quality criterion of the first and / or second film material and / or a process stability criterion. It is conceivable that several target variables are taken into account in the prioritization process. The planned manufacturing processes can, for example, comprise an order list of film materials to be produced.The prioritization process allows the subsequent process to be automatically determined from the planned manufacturing processes in order to align the subsequent process with the ongoing manufacturing process. This can simplify process changeovers. During the prioritization process, a parameter comparison of the process parameter set of the ongoing manufacturing process can be performed with the parameter sets of the planned manufacturing processes. For example, the recipes of the planned manufacturing processes can be checked during the prioritization process for similarity to the recipe of the ongoing manufacturing process. This can reduce material waste and / or the complexity of the process changeover for the operator during the process changeover.Within the scope of the invention, it is further conceivable that the output of the display data and / or the determination of the recommended action takes place as a function of historical data comprising process parameter sets and / or user interactions from previous manufacturing processes, and / or reference data comprising at least one process parameter set and / or user interactions of a reference change for the process change. The reference change can in particular be a recorded process change, in particular one in which the same or similar recipes were available compared to the current process change. For example, the reference change can be carried out manually for recording by an experienced operator, such as a so-called lead operator. This allows other operators who have less experience with process changes to be guided to carry out the process change based on the reference change.For example, the action sequences and / or the process flow can be determined based on the reference change. Reference data of the reference change is preferably output and / or displayed with the display data, in particular with the comparison elements. This allows the operator to see at any time how their process control and / or timing compares to the reference change. It is also conceivable for the history data to form a reference. The process flow can be optimized based on previous manufacturing processes and / or process changes. For example, the process flow can be planned based on a majority of the history data and / or by averaging the history data. The control system can preferably have artificial intelligence, in particular in the form of an artificial neural network. The history data and / or the reference data can form training data for the artificial intelligence.Preferably, the process parameter set and the target subsequent parameter set can be fed to the artificial intelligence as input data in order to obtain the planning of the process flow and / or the at least one action sequence as output data. This allows the method to be designed to be self-learning.

[0033] Advantageously, a method according to the invention can provide for execution data of the user interaction and / or the process change, in particular depending on the sensor data, to be stored as part of the history data for further subsequent processes. The execution data can comprise material data, the process parameter set, the target subsequent parameter set, at least one quality criterion and / or further process data. Thus, the user interaction and / or the current process change can be incorporated into the database available to the control system, thereby improving, in particular, the know-how of operating the extrusion device. In particular, if the sensor data is stored with the execution data, a system reaction to the user interaction can also be recognized and evaluated. In particular, the evaluation based on the sensor data can be saved with the execution data.For example, artificial intelligence can be trained using the execution data. This allows the process to be self-learning. Furthermore, it can be provided that operator behavior is analyzed based on the execution data in order to determine further recommended action and / or update the process flow based on the execution data.

[0034] Preferably, in a method according to the invention, it can be provided that an artificial intelligence is provided, to which the process parameter set and the target subsequent parameter set are fed as input data in order to obtain the comparison data and / or the recommended action as output data, and / or that the implementation data and / or the history data with the sensor data, the process parameter set and the target subsequent parameter set are fed to the artificial intelligence as training data, in particular in order to feed the artificial intelligence the input data for further subsequent processes and to obtain the output data. Preferably, the control system, in particular a control unit of the control system, can have the artificial intelligence, in particular in the form of an artificial neural network. The artificial intelligence can create a self-learning system.Furthermore, artificial intelligence can process large amounts of data to optimize process changes.

[0035] Furthermore, in a method according to the invention it is conceivable that a

[0036] Authentication process is carried out to identify an operator's authorization, wherein the output of the display data and / or the determination of the

[0037] Recommended actions are issued depending on the authentication process. In particular, the control system can comprise different user groups with different rights. During the authentication process, the operator himself or an authorization group can be identified. During the identification of the operator, it can be checked whether the operator is assigned to one of the authorization groups and / or which of the authorization groups the operator is assigned to. For example, the level of detail for the recommended actions in the display data can be determined based on the authentication process. Furthermore, it is conceivable that the display data can be personalized based on the identification of the authorization. This allows the recommended actions to be personalized to simplify process changes for the operator.Furthermore, recipes and / or user interfaces can have write protection, which can be lifted depending on the authentication process. Furthermore, it can be provided that the process flow and / or the reference change can be changed depending on the operator's authorization.

[0038] Furthermore, in a method according to the invention, it can advantageously be provided that a balancing of a quantity of the first film material and / or a quantity of a material ingredient introduced into the extrusion device takes place, in particular wherein the determination of the recommended course of action and / or the planning of the process sequence takes place as a function of the balancing. The balancing can take place for the part of the manufacturing process that has already been carried out. In particular, the manufacturing process can be divided into several process phases, for which the balancing is carried out separately. For example, the process phases can comprise a start phase for starting the manufacturing process, a good production, a bad production and / or phases of different film qualities. In particular, the quantity of the first film material and / or the introduced material ingredient can be measured for balancing.The quantity of the first film material and / or the introduced material ingredient can include a weight. The quantity of the first film material can also be determined by determining the produced linear meters of the first film material, a produced area of ​​the first film material, and / or a number of produced rolls. The quantity of the introduced material ingredient can be measured, for example, in and / or upstream of one or more extruders of the extrusion device. However, it is also conceivable for the balancing to be performed based on one or more user inputs. A prompt can be issued to the user for this purpose.

[0039] Preferably, in a method according to the invention it can advantageously be provided that, preferably for determining the recommended action, a process turning point is determined on the basis of the balancing and / or the end of the process, beyond which a continuation of the manufacturing process while adhering to a quality criterion and / or a process stability criterion of the first film material is no longer possible. After the process turning point, a process change to the subsequent process is preferably enforced, in particular electronically. For example, an extension of the manufacturing process can be initiated automatically and / or by an operator before the process turning point and / or prevented, in particular electronically, after the process turning point. The process turning point can be output as information for an operator, in particular displayed with the display data. In particular, the process turning point can prevent, for example,For example, due to user interaction during the manufacturing process, poor production occurs unnoticed, which then reverts to good production due to a subsequent extension of the manufacturing process. Furthermore, it can be provided that confirmation of the process turning point by an operator is expected, particularly before issuing the recommended action and / or before user interaction. This can prevent the process turning point from being reached without the operator's consent, particularly through the preparatory measure.

[0040] Furthermore, within the scope of the invention, it is conceivable that a material flow within the extrusion device for the process change is determined as a function of the process parameter set and the target process parameter set, wherein the determination of the comparison data, the planning of the process sequence and / or the determination of the recommended action are carried out as a function of the material flow. When determining the material flow, the material flow can advantageously be calculated, in particular analytically and / or numerically, and / or determined empirically. For example, it is conceivable that an observed material flow is extrapolated over a specific period of time. To determine the material flow, information about boundary conditions and / or material ingredients can be provided by the process parameter set and the target process parameter set.For example, based on the process parameter set and the target process parameter set, it can be determined whether certain actions, such as a rinsing process, are required for the process change in order to set up the subsequent process based on the target process parameter set. These actions can determine the material flow, e.g. of a rinsing material. It can be provided that, depending on the material flow, an operator query is made as to the point in time at which a material ingredient and / or the rinsing material should reach the film bubble. Furthermore, it is conceivable that material data, in particular for mapping a material behavior, of at least one first material ingredient used in the manufacturing process can be determined based on the process parameter set, and subsequent material data, in particular for mapping a material behavior of at least one second material ingredient used in the subsequent process instead of the first material ingredient, can be determined based on the target process parameter set.This allows the material flow to be simulated, in particular, to calculate the process flow at least partially in advance. This allows for improved preparation of the comparison data and / or recommended actions.

[0041] According to a further aspect of the invention, a computer program product is provided which comprises instructions which, when executed by a control system, cause the control system to carry out a method according to the invention.

[0042] Thus, a computer program product according to the invention brings with it the same advantages as have already been described in detail with reference to a method according to the invention. The method can in particular be a computer-implemented method. The computer program product can be implemented as computer-readable instruction code. Furthermore, the computer program product can be stored on a computer-readable storage medium such as a data disk, a removable drive, a volatile or non-volatile memory, or a built-in memory / processor. Furthermore, the computer program product can be provided or made available in a network such as the Internet, from which it can be downloaded by a user or executed online as needed. The computer program product can be implemented both by means of software and by means of one or more special electronic circuits, i.e.be implemented in hardware or in any hybrid form, ie using software components and hardware components.

[0043] According to a further aspect of the invention, a system for user guidance is provided. The system comprises an extrusion device for carrying out a manufacturing process for producing a first film material. Furthermore, the system comprises a control system for carrying out a method according to the invention. Thus, a system according to the invention brings with it the same advantages as have already been described in detail with reference to a method according to the invention and / or a computer program product according to the invention. The control system can preferably have a control unit, in particular with a processor and / or microprocessor, for carrying out the method. Furthermore, the control unit can be integrated into a control device of the extrusion device and / or into a control center. The control center can comprise a server and / or a cloud.Furthermore, it is conceivable for the control system to have a plurality of control units, in particular distributed ones, for executing the method. Furthermore, the control system may comprise a storage unit and / or a database for providing the target parameter set, the history data, and / or the reference data. The system may further comprise a display device for displaying the display data. For example, the display device may comprise a display and / or a touchscreen. The display device may advantageously be integrated into the extrusion device and / or the control center. Furthermore, it is conceivable for the display device to be a mobile device, such as a smartphone or a pager.

[0044] Further advantages, features, and details of the invention will become apparent from the following description, which describes embodiments of the invention in detail with reference to the drawings. The features mentioned in the claims and in the description may be essential to the invention individually or in any combination. They show schematically:

[0045] Figure 1 shows a system according to the invention when carrying out a method according to the invention,

[0046] Figures 2a+b parts of an extrusion device of the system during a process change,

[0047] Figure 3 shows a process flow during the process change,

[0048] Figure 4 shows user interactions of the process flow for the process change, Figure 5 shows a correction of the process flow after a system reaction, and

[0049] Figure 6 shows the process in a schematic representation of process steps.

[0050] In the following description of some embodiments of the invention, the same reference numerals are used for the same technical features even in different embodiments.

[0051] Figure 1 shows a system 1 according to the invention during the execution of a method 100 according to the invention for user guidance for a process change from a manufacturing process 200 to support at least one process change from a manufacturing process 200 for producing a first film material 201 to a subsequent process 210 for producing a second film material 211 in a first exemplary embodiment. The manufacturing process 200 for producing a first film material 201 is carried out by the extrusion device 10. As shown in Figures 2a and 2b, the extrusion device 10 comprises a plurality of extruders 11 for extruding a plastic material. Furthermore, the extrusion device 10 has a plurality of feed devices 12, through which the extruders 11 are fed with different material ingredients 206.As shown in Figure 2b, the extrusion device 10 in the present embodiment is a blown film machine with a film blowing head 14 for producing a film bubble, in the region of which the first film material 201 cools. However, it is also conceivable that the extrusion device 10 of the system 1 is, for example, a cast film machine.

[0052] When an order for the production of the first film material 201 is completed, the process changeover takes place from the manufacturing process 200 of the first film material 201 to the subsequent process 210 of the second film material 211 without stopping the extrusion device 10. As shown in Figure 2b, the process changeover can comprise a transition from the first film material 201 to the second film material 211. The transition can, for example, be stepless and / or can be achieved by executing an intermediate process 200.3 for producing an intermediate material 211.1 in order to simplify and / or enable the process changeover. To support the process changeover from the manufacturing process 200 to the subsequent process 210, the system 1 has a control system 20, in particular with a control unit 23 in the form of a processor and / or microprocessor, for carrying out the method 100.Preferably, a computer program product may be provided that includes instructions that, when executed by the control system 20, cause the control system 20 to execute the method 100. Method steps of the method 100 are shown schematically in Figure 6.

[0053] In the method 100, a process parameter set 202 of the manufacturing process 200 for producing the first film material 201 by the extrusion device 10 is first recorded 101. The process parameter set 202 can preferably include sensor data 207 from sensors 13 of the extrusion device 10. Thus, the process parameter set 202 can include actual machine data of the extrusion device 10, which is at least partially measured directly on the extrusion device 10. Furthermore, the process parameter set 202 can include default data for the manufacturing process 200. For example, the process parameter set 202 can include material data of material ingredients 206, i.e. in particular raw materials, and / or control and / or regulation data for controlling the extrusion device 10 by the control unit. The manufacturing process 200 can be defined, preferably completely, by the process parameter set 202.

[0054] Furthermore, in the method 100, a target subsequent parameter set 212 of the subsequent process 210 is determined 102, said target subsequent parameter set being assigned to the process parameter set 202. As shown in Figure 1, the process parameter set 202 comprises, in particular, a plurality of process parameters 202.1. For each of the process parameters 202.1, the target subsequent parameter set 212 can comprise a target subsequent parameter 212.1. Consequently, the subsequent process 210 can be defined, preferably completely, by the target subsequent parameter set 212. The subsequent process 210 can be recorded by a user input and / or retrieved from a storage unit 21 of the control system 20. Advantageously, when determining 102 the target subsequent parameter set 212, parameter sets of a plurality of planned manufacturing processes 200.1 can be determined. The planned manufacturing processes 200 can be stored as an order list in the storage unit 21 of the control system 20.The follow-up process 210 can be determined by performing a prioritization process in which the planned manufacturing processes 200.1 are compared based on at least one target variable. One of the planned manufacturing processes 200.1 can be determined as the follow-up process 210 for the current manufacturing process 200, which is as optimal as possible with respect to the target variable. It is conceivable that an order of the planned manufacturing processes 200.1 is established when determining 102 the target follow-up parameter set 212.

[0055] Based on a comparison of the process parameter set 202 with the target subsequent parameter set 212, the method 100 further comprises, in particular by the control unit 23, determining 103 comparison data 221 to detect deviations of the target subsequent parameter set 212 from the process parameter set 202. For example, a difference between the target subsequent parameters 212.1 and the process parameters 202.1 can be determined in order to determine, for example, control data and / or system adjustments that enable the process change. The comparison data 221 form a basis for displaying comparison elements 221.1.

[0056] Depending on the comparison data 221, at least one process sequence 203 for the manufacturing process 200 and / or the subsequent process 210 is further planned 104. The process sequence 203 is shown in Figure 3. The process change comprises, in particular, the intermediate process 200.3, in which an intermediate material 211.1 is produced to enable a transition from the first film material 201 to the second film material 211. During the production of the intermediate material 211.1, for example, material ingredients 206 of the second film material 211 can be gradually added.

[0057] As shown in Figure 4, the process flow 203 further defines, in particular, temporal changes in a temporal progression of the process parameter set 202 over a time t. The process flow 203 includes a sequence of user interactions 233 and the resulting system reactions of an at least partial adaptation of process parameters 202.1 to the respectively assigned target subsequent parameter 212.1.

[0058] Based on the process flow 203, in particular by the control system 20, a determination 105 of at least one recommended action 232 is carried out depending on the comparison data 221. The recommended action 232 comprises information for recommending a user interaction 233 in the form of a manual activity and / or a control of the extrusion device 10. It can be provided that when determining 105 the recommended action 232, several recommended actions 232 are determined to define an action sequence 234 with a chronological order of the recommended actions 232, in particular based on the process flow 203. To define the action sequence 234, the chronological course of the process parameter set 202 is taken into account when determining 103 the recommended actions 232. This makes it possible to define the optimal sequence for the process change at the time of determining 105 the recommended action 232.It is advantageous if the action recommendations 232 for defining the action sequence 234 are divided into groups in time to allow for time intervals 234.1 between the groups. This allows an operator to perform the actions in the time intervals.

[0059] 234.1 perform other work, such as operating a second extrusion device 10 or assisting another operator.

[0060] As can be seen from Figure 3, it can be advantageous if certain user interactions 233 of the process change can already be carried out during the manufacturing process 200 and / or prepared by visualization and / or by actions of the operator and / or the control system 20, in particular if the change conditions of the process change are known from the comparison data 220. Furthermore, the user interactions 233 can be carried out at least partially during the intermediate process 200.3. The user interactions 233 can include manual activities and / or control actions for controlling the extrusion device 10. The recommended actions 232 can each contain at least one piece of information for recommending at least one user interaction 233 for a rinsing process 236.1, an adjustment

[0061] 236.2 of a process parameter 202.1 in the form of a temperature of the extrusion device 10 and / or a change 236.3 of the process data 202 to maintain bubble stability of a film bubble, particularly during the temperature adjustment 236.2. Furthermore, it is conceivable that the recommended action 232 includes a change to a material supply 12.1 and / or a start procedure for the intermediate process 200.3.

[0062] For improved prediction of the process sequence 203, a balancing 224 of a quantity of the first film material 201 and / or a quantity of a material ingredient 206 introduced into the extrusion device 10 can be performed. Furthermore, a material flow 225 within the extrusion device 10 for the process change can be determined depending on the process parameter set 202 and the target process parameter set 212. Based on the balancing 224 and / or the material flow 225, the recommended action 232 can then be determined 105 and / or the process sequence 203 can be planned 104. As a result, the process change can be at least partially material-controlled.In particular, to determine 105 the recommended action 232, a process turning point 209 is determined based on the balancing 224 and / or the process completion 204, beyond which a continuation of the manufacturing process 200 while maintaining a quality criterion of the first film material 201 is no longer possible. The process turning point 209 can be output via the display data 231. After the process turning point 209, the process change to the subsequent process 210 can be electronically enforced by the control unit 23.

[0063] For user guidance, the method 100 further comprises outputting 106 of display data 231 for the joint display of a plurality of comparison elements 221.1 for representing the deviations based on the comparison data 221 during the manufacturing process 200. It can be specified that each of the comparison elements 221.1 comprises an individual comparison for each of the process parameters 202.1 with the associated target subsequent parameter 212.1 in the display data 231. Preferably, the comparison elements 221.1 comprise a selection of comparisons of the process parameters 202.1 with the associated target subsequent parameters 212.1 and / or a processing of the comparison of the process parameter set 202 and the target subsequent parameter set 212. For example, the comparison data 221 can comprise a predefined selection of individual comparisons of process parameters 202.1 with the respectively associated target subsequent parameter 212.1 and / or a calculation of key figures for visualizing the comparison.The display data 231 includes the comparison elements 221.1, in particular in the form of a visualization of the comparison data 221, e.g., with graphic elements. As shown in Figure 1, when the display data 231 is output 106, the display data 231 is sent from a control unit 23 of the control system 20 to a display device 22, which displays the comparison elements 221.1 together. Furthermore, the action sequence 234 and / or the recommended action 232 are taken into account in the display data 231. This provides an operator with immediate information about which user interaction 233 should be performed based on the comparison data 221.

[0064] The outputting 106 of the display data 231 and / or the determination 105 of the recommended action 232 can be carried out depending on historical data 250 and / or reference data 223. The historical data 250 can include process parameter sets 202 and / or user interactions 233 of previous manufacturing processes 200.2. The reference data 223 can include at least one process parameter set 202 and / or user interactions 233 of a reference change 251 for the process change. The reference change 251 can be a process change that is or was performed by an experienced operator, in particular a lead operator. The reference data 223 can in particular include a recording of the reference change 251.

[0065] Subsequently, one of the user interactions 233 for controlling the extrusion device 10 is detected 107 to at least partially adapt the process parameter set 202. The user interaction 233 can comprise the specification of an adjusted value for one of the process parameters 202.1 of the process parameter set 202. For example, the user interaction 233 can be in the form of a user input directly on the display device 22 in order to control the extrusion device 10. However, it is equally conceivable for the user interaction 233 to comprise a manual action for controlling the extrusion device 10, such as moving a component, opening a valve, and / or the like. Upon detection 101 of the user interaction 233, in particular, a control instruction and / or a system response of the extrusion device 10 can be recognized.For example, the user interaction 233 can be detected by the process parameter set 202 changing or by a target value being specified for a process parameter 202.1 of the process parameter set 202.

[0066] Depending on the adaptation of the process parameter set 202, preferably during the manufacturing process 200, the method 100 further comprises updating 108 the display data 231. For this purpose, for example, the determination 103 of the comparison data 221 can be repeated using the adapted process parameter set 202. During the updating 108 of the display data 231, in particular the comparison elements 221 are updated, preferably by visualizing the system reactions to the respective user interaction 233, as shown in Figures 4 and 5, using the comparison elements. As shown in Figure 5, the process flow 203 and / or the action sequence 234 can also be updated depending on the user interaction 233.As a result, the process flow 203 can be adapted in the event of unforeseen actions by the operator and / or unforeseen system reactions of the extrusion device 10 in order to navigate the user through the process change as optimally as possible. Provision can be made for an authentication process 237 to identify an operator's authorization, depending on which the display data 231 is output 106 and / or the recommended action 232 is determined 102. As a result, the display data 231 can be individually configurable. Furthermore, it can be ensured that the recommended action 232 is appropriate for the authorization level of the identified operator. For example, an experienced operator can be allowed more freedom during the process change and / or the recommended action 232 can be designed in less detail.

[0067] In particular, depending on the sensor data 207, execution data 252 of the user interactions 233 are preferably stored, in particular as part of the history data 250, for provision for further subsequent processes 210 in the storage unit 22 of the control system 20 in order to achieve a learning effect and an improvement in, in particular, internal, know-how based on the execution data 252. In particular, the control unit 23 can have an artificial intelligence 24, to which the process parameter set 202 and the target subsequent parameter set 212 are supplied as input data in order to obtain the comparison data 221 and / or the recommended action 232 as output data. Additionally or alternatively, the execution data 252 and / or the history data 250 with the sensor data 207, the process parameter set 202, and the target subsequent parameter set 212 of the artificial intelligence 24 can be supplied as training data to the artificial intelligence 24.

[0068] Thus, the method 100 particularly comprises dynamic process control for the interaction of a user with the extrusion device 10, in particular at least partially during the ongoing manufacturing process 200, in order to prepare the subsequent process 210. Certain steps can be performed even before the completion of the manufacturing process 200. By means of the preparatory measures for the process change, the process change can be at least partially shifted into the manufacturing process 200, thus preferably blurring the boundary between the manufacturing process 200 and the subsequent process 210. By jointly displaying the comparison data 221 during the manufacturing process 200, both experienced and inexperienced users can obtain a comprehensive overview of the current process parameter set 202 and the adjustments to be made for the subsequent process 210 at any time.Furthermore, by updating 108 the display data 231, a navigation-like, continuous check can be performed to determine whether the current adjustments meet the requirements of the manufacturing process 200 and / or the subsequent process 210. With each update 108 of the display data 231, the operator can be shown an optimal path for the process change. This allows incorrect operation and / or disadvantageous operating actions to be detected, enabling a counter-reaction.

[0069] The above explanation of the embodiments describes the present invention exclusively by way of examples. Of course, individual features of the embodiments can be freely combined with one another, provided they are technically feasible, without departing from the scope of the present invention.

[0070] Reference number list

[0071] system

[0072] Extrusion device Extruder

[0073] Material supply device

[0074] sensor

[0075] Film blowing head

[0076] Control system Storage unit Display device Control unit

[0077] Proceedings

[0078] Capturing 202

[0079] Determining 212

[0080] Determine 221

[0081] Planning of 203

[0082] Determine 232

[0083] Output of 231 Capture of 233

[0084] Updating from 230

[0085] Manufacturing process planned manufacturing process previous manufacturing process intermediate process first film material process parameter set process parameters

[0086] Process flow material ingredient

[0087] Sensor data

[0088] Follow-up process second film material

[0089] Intermediate material

[0090] Target follow-up parameter set

[0091] Target follow-up parameters

[0092] Comparative data

[0093] Comparison element

[0094] Reference data

[0095] Accounting

[0096] Display data

[0097] Recommendation for action

[0098] User interaction

[0099] Action sequence

[0100] space

[0101] Rinsing process

[0102] Adjusting a temperature

[0103] Amendment of 202 to maintain stability of the film bubble

[0104] Authentication process

[0105] Historical data

[0106] Reference change

[0107] Implementation dates

[0108] Time

Claims

P atentansp ü che Method (100) for user guidance for a process change from a manufacturing process (200) for producing a first film material (201) to a subsequent process (210) for producing a second film material (211) in an extrusion device (10), comprising: - detecting (101) a process parameter set (202) of the manufacturing process (200) for producing the first film material (201), - determining (102) a target subsequent parameter set (212) of the subsequent process (210) assigned to the process parameter set (202), Determining (103) comparison data (221) of a comparison of the process parameter set (202) with the target subsequent parameter set (212) to detect deviations of the target subsequent parameter set (212) from the process parameter set (202), - outputting (106) display data (231) for the joint display of several comparison elements (221.1) for displaying the deviations based on the comparison data (221) during the manufacturing process (200), detecting (101) a user interaction (233) for controlling the extrusion device (10) for at least partially adapting the process parameter set (202), - Updating (108) the display data (231) depending on the adjustment of the process parameter set (202). The method (100) according to claim 1, characterized in that the process parameter set (202) and / or the comparison elements (221.1) comprise material data from material ingredients (206) and / or sensor data (207) from sensors (13) of the extrusion device (10). The method (100) according to claim 1 or 2, characterized in that the method (100) comprises the following step: Determining (105) at least one recommended action (232) for adapting the process parameter set (202), preferably during the manufacturing process (200), for the subsequent process (210) as a function of the comparison data (221), wherein the recommended action (232) is output with the display data (231). Method (100) according to one of the preceding claims, characterized in that the recommended action (232) comprises a manual action and / or a recommendation for controlling the extrusion device (10). Method (100) according to one of the preceding claims, characterized in that the method (100) comprises the following steps: Planning (104) at least one process sequence (203) for the manufacturing process (200) and / or the subsequent process (210) as a function of the comparison data (221), in particular wherein the determination (105) of the recommended action (232) takes place as a function of the process sequence (203). Method (100) according to one of the preceding claims, characterized in that the process sequence (203) for defining temporal changes comprises a temporal progression of the process parameter set (202), wherein the output (106) of the display data (231) and / or the determination (105) of the recommended action (232) takes place as a function of the temporal progression.Method (100) according to one of the preceding claims, characterized in that when determining (105) the recommended action (232), a plurality of recommended actions (232) are determined to define an action sequence (234), in particular wherein the action sequence (234) comprises a chronological order of the recommended actions (232). Method (100) according to one of the preceding claims, characterized in that. that, in order to define the action sequence (234), the temporal progression of the process parameter set (202) is taken into account when determining (103) the action recommendations (232). Method (100) according to one of the preceding claims, characterized in that the action recommendations (232) for defining the action sequence (234) are divided into groups over time in order to allow for time intervals (234.1) between the groups. Method (100) according to one of the preceding claims, characterized in that the process progression (203) and / or the action sequence (234) is updated as a function of the user interaction (233), in particular wherein the updating (108) of the display data (231) takes place as a function of the updated process progression (203). Method (100) according to one of the preceding claims, characterized in that, in determining (102) the target subsequent parameter set (212), parameter sets of a plurality of planned manufacturing processes (200) are used.1), wherein a prioritization process is carried out in which the planned manufacturing processes (200.1) are compared on the basis of at least one target variable in order to define one of the planned manufacturing processes (200.1) as the subsequent process (210). Method (100) according to one of the preceding claims, characterized in that the outputting (106) of the display data (231) and / or the determination (105) of the recommended action (232) takes place as a function of historical data (250) comprising process parameter sets (202) and / or user interactions (233) of previous manufacturing processes (200.2), and / or of reference data (223) comprising at least one process parameter set (202) and / or user interactions (233) of a reference change (251) for the process change. Method (100) according to one of the preceding claims, characterized in that implementation data (252) of the user interaction (233), in particular as a function of the sensor data (207), are stored as part of the history data (250) for provision for further subsequent processes (210). Method according to one of the preceding claims, characterized in that an artificial intelligence (24) is provided, to which the process parameter set (202) and the target subsequent parameter set (212) are supplied as input data in order to obtain the comparison data (221) and / or the recommended action (232) as output data, and / or that the implementation data (252) and / or the history data (250) with the sensor data (207), the process parameter set (202), and the target subsequent parameter set (212) are supplied to the artificial intelligence (24) as training data.Method (100) according to one of the preceding claims, characterized in that an authentication process (237) is carried out to identify an operator's authorization, wherein the output (106) of the display data (231) and / or the determination (105) of the recommended action (232) takes place as a function of the authentication process (237). Method (100) according to one of the preceding claims, characterized in that a balancing (224) of a quantity of the first film material (201) and / or a quantity of a material ingredient (206) introduced into the extrusion device (10) takes place, in particular wherein the determination (105) of the recommended action (232) and / or the planning (104) of the process sequence (203) takes place as a function of the balancing (224). Method according to one of the preceding claims, characterized in that. that, in order to determine (105) the recommended action (232), a process turning point (209) is determined based on the balancing (224) and / or based on the process completion (204), from which turning point a continuation of the manufacturing process (200) while maintaining a quality criterion of the first film material (201) is no longer possible. Method according to one of the preceding claims, characterized in that a material flow (225) within the extrusion device (10) for the process change is determined as a function of the process parameter set (202) and the target process parameter set (212), wherein the determination of the comparison data (221), the planning (104) of the process sequence (203) and / or the determination (105) of the recommended action (232) is carried out as a function of the material flow (225).A computer program product comprising instructions that, when executed by a control system (20), cause the control system (20) to execute a method (100) according to any one of the preceding claims. A system (1) for user guidance for a process change, comprising an extrusion device (10) for performing a manufacturing process (200) for producing a first film material (201), and a control system (20) for performing a method (100) according to any one of claims 1 to 18.

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