Method for supporting the execution of a process change, computer program product and system

Abstract

The invention relates to a method (100) for supporting the execution of a process change 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 supporting the implementation of a process change, computer program product and system

[0002] Description

[0003] The invention relates to a method for supporting the implementation of 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, a computer program product, and a system.

[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 carry out the changeover from one recipe to the subsequent recipe are based exclusively on the knowledge of the machine operator. This can result in a very high scrap rate for this changeover between recipes, especially with 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. DE 10 2015 108 974 A1 therefore discloses the possibility of predetermining a process limit in the form of the end of a production order and specifying a reduced changeover fill level in anticipation of this end of the production order. This can reduce material scrap due to excess material during a process changeover.However, the material is viewed primarily from the perspective of the input material. It would be desirable to optimize further aspects of a process change.

[0006] 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 improve the planning and / or execution of a process change in an extrusion device by increasing prediction accuracy.

[0007] The above object is achieved by a method having the features of claim 1, a computer program product having the features of claim 19, and a system having the features of claim 20. 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.

[0008] According to a first aspect of the invention, a method is provided for supporting the implementation of 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. The method comprises, in particular in the form of method steps:

[0009] Recording of process data of the manufacturing process, in particular through a control system,

[0010] - Acquisition of subsequent process data of the subsequent process, in particular by the control system, - Predetermination of at least one material flow within the extrusion device for the process change depending on the process data and / or the subsequent process data, in particular by the control system,

[0011] - Carrying out at least one preparatory measure to cause at least one process change event depending on the material flow, in particular by the control system.

[0012] 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.

[0013] 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 together.

[0014] 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.

[0015] The process data can comprise a process parameter set with 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, a pressure in an extruder, and / or an extruder rotational speed. It can be provided that the process parameter set executes continuous or discontinuous control and / or regulation of the extrusion device when controlling the extrusion device during the manufacturing process. For this purpose, the process parameter set can be transmitted from the control system to the extrusion device, in particular to components of the extrusion device.

[0016] The subsequent process data can comprise a target subsequent parameter set with one or more subsequent process 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, a pressure in an extruder, and / or an extruder rotational speed. Thus, the target subsequent parameter set can comprise one or more subsequent process parameters that are assigned to the one or more process parameters of the process parameter set, but relate to the subsequent process. Furthermore, the subsequent process data can comprise material data, such as material properties of the second film material and / or a material ingredient for the second film material, for the subsequent process.When recording the downstream process data, the downstream process data can be retrieved, for example, from a storage unit and / or a database. However, it is also conceivable for the downstream process data to be recorded via user input, particularly on the extrusion device. Based on the process data and the downstream process data, it can also be determined whether the process change involves a format and / or material change.

[0017] When predicting the material flow, the material flow can advantageously be calculated and / or determined empirically, in particular analytically and / or numerically. For example, it is conceivable that an observed material flow is extrapolated over a specific period of time. The material flow can depict a movement of at least one or more material ingredients for the first and / or second film material. To predict the material flow, information about boundary conditions and / or material ingredients can be provided by the process data and the subsequent process data. For example, the process data and the subsequent process data can be used to determine 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 subsequent process data. These actions can determine the material flow, e.g. of a rinsing material.Furthermore, it is conceivable for the process data to comprise material data of at least one first material ingredient used in the manufacturing process, and for the subsequent process data to comprise subsequent material data of at least one second material ingredient used in the subsequent process instead of the first material ingredient. The material flow can depict a movement of a yield point between the first and second material ingredients. The event is, in particular, a process event. For example, the event can comprise reaching a specific value of a process parameter and / or the arrival of a material ingredient at an event location. In particular, it is conceivable for the event to comprise a change in the first material ingredient, in particular to the second material ingredient, in a device section of the extrusion device.

[0018] The preparatory measure is preferably carried out automatically depending on the material flow. In particular, the preparatory measure is carried out during the manufacturing process, i.e. before the process change and / or the completion of the manufacturing process. The preparatory measure can be designed to automatically carry out and / or support an at least partial adaptation of the current process data to the subsequent process data. The material flow determines in particular a significant part of the process change, since the material ingredients involved move within the extrusion device from a material supply to an outlet for the respective film material produced. It has therefore been recognized within the scope of the invention that this can be used to coordinate the preparatory measure with the material flow in order to enable an efficient process change.For example, a material change of a material ingredient in a feed device can be initiated before the manufacturing process is complete. Because the preparatory measure is carried out depending on the determined material flow, the event can be triggered, for example, when a follow-up material replaces a feed material at a specific point in the extrusion device. This can shorten the time required for the process change. For example, it is conceivable that the preparatory measure is already carried out during the manufacturing process in order to be able to continue production for as long as possible during the process change, preferably without being affected by the manufacturing process, especially if follow-up material is already in the extrusion device. Due to the complexity of film production, actions can also have an impact on several process parameters.On the basis of the material flow, the method according to the invention enables, in particular, a consideration of the process change as a holistic process in which sub-processes can take place in parallel and / or in a coordinated manner in order to be able to exploit and / or coordinate the mutual influence of the material flow and the at least one event.

[0019] Furthermore, in a method according to the invention, it can advantageously be provided that the preparatory measure comprises automatic control of the extrusion device and / or output of a recommended action for execution by an operator. For automatic control of the extrusion device, a signal for controlling and / or regulating the extrusion device for the manufacturing process can be sent from the control system to the extrusion device and / or a component of the extrusion device. The control signal can comprise an adjustment of the process parameter set, in particular in the form of target process parameters and / or target profiles of process parameters. The automatic control can create time for an operator, which the operator can use to carry out further preparatory measures, such as, for example, procuring materials.The recommended action can, for example, include an instruction for performing a manual task. The recommended action can be output, for example, by displaying the recommended action on a display device, particularly in the form of a visualization. The recommended action can preferably be visualized depending on the type of process change. Based on the type of process change, it is possible to distinguish whether the process change involves a material and / or format change. The recommended action can be used to implement user guidance during the process change to instruct an operator of the extrusion device.

[0020] Within the scope of the invention, it is further conceivable that the material flow is predicted using a calculation model for a material distribution and / or a material movement in the extrusion device. The calculation model can be predefined and / or stored, for example, in a memory unit of the control system. The calculation model can be designed for the analytical and / or numerical calculation of the material flow. It is conceivable that the calculation model comprises geometric data of the extrusion device. Preferably, the calculation model maps a movement path of the material flow, so that the material flow can be calculated along the movement path depending on control data of the extrusion device. To predict the material flow, material data, such as a viscosity and / or a melt flow index, can be taken into account by the calculation model.The calculation model allows for a high degree of accuracy in predicting material flow. In particular, material flow predictions can be determined to trigger the event depending on the material flow and / or to coordinate the material flow and the event.

[0021] Furthermore, in a method according to the invention, it is conceivable that the event can be caused or is caused by carrying out the preparatory measure at an event location of the extrusion device, and that the execution of the preparatory measure is coordinated in time with the material flow, so that the material flow correlates in time with the event at the event location. The event location comprises, in particular, a device section of the extrusion device. For example, the event location can comprise a material outlet and / or a material inlet of an extruder, a melt gap and / or a section of a film bubble. It can be provided that, when determining the material flow in advance, a conveying time of a material ingredient for the second film material and / or the rinsing process up to the event location for the first film material is calculated and the material change and / or the rinsing process takes place as a function of the conveying time.For example, the material flow can be used to determine when the material ingredient reaches the film bubble from a feed device. By coordinating the preparatory action with the material flow, the film bubble can be stabilized in a timely manner and / or it can be predicted how long the first film material will continue to be produced without the material ingredient. The improved coordination between the event and the material flow can therefore achieve high accuracy in controlling the process changeover, minimizing changeover time and / or improving process stability.

[0022] Furthermore, in a method according to the invention, it can advantageously be provided that the material flow comprises a movement of a material in the extrusion device up to the event location, wherein the event comprises reaching a target value of a process parameter, in particular at the event location. The target value can, for example, comprise a degree of homogeneity in the film bubble, a specification of a temperature value, a speed value of an extruder and / or an extruder pressure. For example, it may be necessary for a predetermined temperature to be reached at a device section of the extrusion device when one material ingredient of the second film material reaches the device section. Depending on a component of the extrusion device assigned to the device section, a temperature change, i.e. in particular a heating or cooling, of the device section can require a period of time.The preparatory measure can include controlling the device section to change the temperature to the target value. The preparatory measure can be timed to coincide with the material flow so that the temperature change is complete, i.e. the target value is reached, when the material reaches the device section. This can ensure that the material in the preparatory section has sufficient viscosity to enable the material to be conveyed further and / or mixed thoroughly. At the same time, material previously in the device section can be exposed to no or only a slowly increasing influence of the temperature change for as long as possible. This can ensure that the process change is particularly sharp-edged by producing the first film material as good production for as long as possible, taking a quality criterion into account.

[0023] Furthermore, in a method according to the invention, it can advantageously be provided that the preparatory measure comprises at least one, several or all of the following exchange processes at least partially or completely:

[0024] - Change of a material stock, in particular to change a material ingredient,

[0025] - Adjusting a temperature of the extrusion device, in particular a device section of the extrusion device,

[0026] - Change of process data to maintain bubble stability of a film bubble, especially during temperature adjustment and / or by changing a manufactured film format,

[0027] - Starting process for an intermediate process for producing an intermediate material, in particular for carrying out a rinsing process.

[0028] When changing the material supply, for example, a suction lance for sucking in a material ingredient can be switched between two storage containers in order to change the material ingredient. Furthermore, a target fill level can be specified to change the material supply so that the event occurs in the form of an emptying or near-emptying of the material supply and a predetermined material quantity of the first film material is reached. When adjusting the temperature of the extrusion device, for example, a film blow head of the extrusion device can be heated up or cooled down in preparation for a material change. When changing the process data to maintain bubble stability, for example, a film format can be changed by adjusting a film thickness and / or a tube diameter. This can prevent the extruded material in the film bubble from becoming too thin and tearing the film bubble.By maintaining bubble stability, the ongoing process can be maintained and a restart of the extrusion device can be prevented. It is also conceivable that, depending on the material flow, a material change sequence of several extruders of the extrusion device is defined for the material change in order to maintain a production process of the extrusion device. During the start-up process for the intermediate process, for example, a rinsing process can be initiated. Furthermore, it is conceivable that the intermediate process is designed as a transition process between the production process and the subsequent process. For example, a gradual addition of material ingredients from the subsequent process and / or a gradual change from material ingredients from the production process to material ingredients of the subsequent process can take place in the intermediate process. The intermediate process can be started during the start-up process, e.g. by an initial material change.The changeover processes allow the actions required for the process change to be executed and coordinated with the material flow. This allows the process change to be carried out with high efficiency, particularly with a reduction in changeover time.

[0029] In a method according to the invention, it can preferably be provided that the preparatory measure comprises a plurality of changeover processes for carrying out the process change, in particular wherein the changeover processes are prioritized and / or output one after the other when carrying out the preparatory measure. By carrying out a plurality of changeover processes during the preparatory measure, a substantial part of the process change or the entire process change can be carried out depending on the material flow. When prioritizing the changeover processes, a sequence of the changeover processes can be determined. The prioritization can take place depending on the material flow, the process data and / or the subsequent process data. In this case, the prioritization can take place depending on a target variable, in particular a changeover time and / or a quality criterion of the first and / or second film material.For example, prioritization can be used to determine which extruder a purge process is performed for first. The output of the changeover actions can also be implemented in the form of automated control of the extrusion device and / or a display of recommended actions. By performing multiple changeovers, the process changeover can be planned in advance to achieve improved coordination of the individual changeovers, particularly with regard to the material flow and / or the event.

[0030] It is further conceivable in a method according to the invention that the preparatory measure, in particular the changeover processes, are determined based on a recording of a reference change, in particular from the process data to the subsequent process data. The reference change can in particular be a recorded process change, in particular one in which the same or similar recipes were present compared to the current process change. For example, the reference change can be carried out manually by an experienced operator, such as a so-called lead operator, for recording purposes. 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.The reference data can provide a beneficial starting point for the preparation measures, allowing individual experience in operating the extrusion device and / or in implementing various film formulations to be incorporated into the preparation process. This allows specific know-how to be incorporated into the process.

[0031] Preferably, a method according to the invention can provide for an artificial intelligence to which the process data and the subsequent process data are fed as input data in order to obtain the material flow and / or the preparatory measure as output data, and / or that the execution data and / or the process history with the sensor data, the process data and / or the subsequent process data 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 comprise 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.

[0032] In a method according to the invention, it can preferably be provided that the preparatory measure comprises a rinsing process of at least part of the extrusion device, in particular wherein the material flow comprises a movement of a rinsing material of the rinsing process. During the rinsing process, the extrusion device can be at least partially or completely cleaned for a material change, in particular by producing an intermediate product with the rinsing material. During the rinsing process, material residues of a material ingredient of the first film material can thus be removed from the extrusion device in order to prevent contamination of the second film material. It can be provided that a material type of the rinsing material and / or a rinsing time is determined depending on the material flow. In this way, for example, the rinsing time and / or a selection of the material type of the rinsing material can be optimized.

[0033] It is further conceivable in a method according to the invention that a purging time of the purging process is calculated depending on the process data and the material flow, wherein the preparatory measure is carried out depending on the purging time. The purging time can, in particular, comprise a period of time for carrying out the purging process. Depending on the purging time, a completion of the purging process can, in particular, be calculated in advance. Furthermore, depending on the material flow and / or the purging time, several different purging materials of the purging process can be coordinated, e.g., for purging several different extruders and / or feed devices.The preparatory measure may, for example, include introducing a material ingredient for the second film material into the extrusion device and / or stopping a material supply of the purging material to the extrusion device, in particular so that immediately after completion of the purging process, a material ingredient reaches the film bubble to produce the second film material and / or an intermediate material. This can ensure that the purging process is carried out for a sufficient period of time and, at the same time, optimizes the timing for subsequent material ingredients.

[0034] Furthermore, in a method according to the invention, it can advantageously be provided that a process completion of the manufacturing process is calculated in advance as a function of the material flow, in particular wherein the event is assigned to the process completion. The process completion of the manufacturing process can be understood in particular as the completion of a commissioned and / or carried out good production of the first film material. The process completion itself can form the event or correlate with the event. For example, the preparatory measure can initiate a material change, which is carried out on the film bubble immediately following the process completion. Based on the material flow, a material quantity and / or a material speed for a material outlet, such as a melt gap, can be calculated in advance for a specific point in time.Assuming that production is carried out unchanged or essentially unchanged, a second point in time can be calculated, for example, starting from a first point in the manufacturing process, at which sufficient material flow has been generated to complete the manufacturing process. Thus, the material flow can be used to predict when the process will be completed even before the required first film material is actually produced.

[0035] Furthermore, in a method according to the invention, it is conceivable that the preparatory measure is determined as a function of a predetermined target variable for the transfer of the extrusion device, in particular wherein the target variable comprises a material quantity, a changeover time of 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, i.e. in particular a raw material, for the first and / or second film material. However, it is also conceivable that the target variable comprises a material quantity of a film material produced by the extrusion device, i.e. in particular a starting material. The changeover time can be understood in particular as a time span between a good production of the first film material and a good production of the second film material.The quality criterion can be a geometric criterion, such as a film thickness and / or a film width. However, it is also conceivable for the quality criterion to include at least one material property, such as a relaxation parameter, a tensile and / or tear strength and / or film transparency. Furthermore, the quality criterion can be an economic criterion, such as material costs. Process reliability can be understood, for example, as security against film tear during a process change and / or reproducibility of the process change. To determine the preparatory measure, an optimization process can be carried out with regard to the target variable depending on the material flow, the process data and the subsequent process data. For this purpose, a variation of at least one changeover action can be carried out and / or simulated depending on the target variable.Thus, the process change can be optimized with regard to the target size.

[0036] 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 preparatory measure and / or the calculation of the process completion takes place as a function of the balancing. The balancing can take place for the part of the production process that has already been carried out. In particular, the production 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 production 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 comprise a weight. The quantity of the first film material can further be determined by determining the produced running 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 carried out based on one or more user inputs. For this purpose, an input prompt can be issued to the user. To determine the preparatory measure, a process turning point can preferably be determined based on the balancing and / or the process completion, beyond which a continuation of the production process while maintaining the quality criterion of the first film material is no longer possible.For example, an extension of the manufacturing process can be initiated before the process turning point. The process turning point can be output, in particular displayed, as information to an operator. Furthermore, it can be provided that confirmation of the process turning point from an operator is expected before the preparatory measure is carried out. This can prevent the process turning point from being reached without the operator's consent, in particular through the preparatory measure.

[0037] It is further conceivable in a method according to the invention that the balancing is carried out depending on the prediction of the material flow for a point in time in the future at the time of balancing. Based on the material flow, it can be determined in advance which quantity of the first and / or second film material will have left the extrusion device at the future point in time and / or which quantity of one or more material ingredients for the first and / or second film material will have been introduced into the extrusion device at the future point in time. This allows a high degree of accuracy to be used to predict the quantities of material produced and / or consumed in order to design and / or optimize the process changeover. Furthermore, the balancing can be used to predict the end of the process with high precision.

[0038] Furthermore, in a method according to the invention it can advantageously be provided that the method comprises:

[0039] Acquisition of sensor data for detecting a change in the manufacturing process that occurs as a function of the preparatory measure, in particular by the control system, in particular wherein the sensor data are monitored with regard to the target variable and / or the determination of the material flow is updated as a function of the sensor data. Preferably, the preparatory measure is interrupted and / or a countermeasure is carried out if it is determined from the sensor data that a process condition related to the target variable is not met. The sensor data can, for example, include 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. Based on this, it can be detected at any time how far the process change on the extrusion device has been implemented. Furthermore, the sensor data can include image data from a camera, in particular for detecting a bubble shape.For example, the process condition may include maintaining a bubble shape to prevent film tear and thus interrupting the manufacturing process. To detect bubble stability, vibrations and / or tumbling of the film bubble can be evaluated based on the sensor data. Thus, the sensor data can be used to monitor the impact of the preparatory measure on the manufacturing process.

[0040] Preferably, a method according to the invention can provide for the material flow and / or the preparatory measure to be determined based on a process history of previous manufacturing processes. The process history can comprise a database in which process data and / or change actions from previous process changes are stored. Using the process data of the ongoing manufacturing process and / or the subsequent process data of the subsequent process, the database can be examined for similarities. Furthermore, the database entries can be evaluated with regard to the target variable. Based on the process history, it is therefore not necessary for an operator to have the know-how to carry out the process change themselves. Rather, internal company know-how from previous process changes can be used to define the preparatory measure.

[0041] Furthermore, in a method according to the invention, it can advantageously be provided that implementation data of the preparatory measure, in particular depending on the sensor data, is stored as part of the process history for provision for further downstream processes. The implementation data can comprise the material data, the process parameter set, the target downstream parameter set, the at least one quality criterion and / or further process data. Thus, the preparatory measure and / or the current process change can be incorporated into the database available to the control system and thus, in particular, the know-how of operating the extrusion device can be improved. In particular, if the sensor data are saved with the implementation data, a system reaction to the preparatory measure can also be detected. In particular, the evaluation based on the sensor data can be saved with the implementation data.Thus, the process can be designed to be self-learning.

[0042] Within the scope of the invention, it is further conceivable that the method comprises:

[0043] Determining the subsequent process based on a process collection for producing different film materials by analyzing the process collection based on the process data and the subsequent process data.

[0044] In particular, the subsequent process can be determined depending on the target variable. It is conceivable that several target variables are taken into account when determining the subsequent process. The process collection can comprise several planned manufacturing processes, for example in the form of an order list of film materials to be produced. By determining the subsequent process, the subsequent process can be automatically determined from the planned manufacturing processes in order to coordinate the subsequent process with the ongoing manufacturing process. This can simplify process changes. When analyzing the process collection, a parameter comparison of the process data of the ongoing manufacturing process can be carried out with process data of the planned manufacturing processes. For example, the recipes of the planned manufacturing processes can be checked for similarity to the recipe of the ongoing manufacturing process during the prioritization process.Furthermore, the process collection can be sorted to determine the subsequent process in order to establish a sequence of manufacturing processes. Determining the subsequent process based on the process collection can reduce material waste and / or the complexity of the process change for the operator during the process change, especially if the greatest possible similarity is achieved between the manufacturing process and the subsequent process.

[0045] 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.

[0046] 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.

[0047] 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.

[0048] 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 unit 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 several, in particular distributed, control units for carrying out the method. Furthermore, the control system can comprise a storage unit and / or a database for providing the desired follow-up parameter set. The system can further comprise a display device for displaying information.For example, the display device can comprise a display and / or a touchscreen. The display device can advantageously be integrated into the extrusion device and / or the control center. Furthermore, it is conceivable that the display device is a mobile device, such as a smartphone or a pager.

[0049] 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:

[0050] Figure 1 shows a system according to the invention when carrying out a method according to the invention,

[0051] Figures 2a+b parts of an extrusion device of the system during a process change,

[0052] Figure 3 shows a process flow during the process change, and

[0053] Figure 4 shows the process in a schematic representation of process steps.

[0054] 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.

[0055] Figure 1 shows a system 1 according to the invention executing a method 100 according to the invention for supporting 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 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.

[0056] 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 4.

[0057] In the method 100, a recording 101 of process data 202 of the manufacturing process 200 and a recording 102 of subsequent process data 212 of the subsequent process 210 takes place. The process data 202 comprise in particular a process parameter set with one or more process parameters 202.1 of actual machine data and / or target machine data of the extrusion device 10, in particular in the form of sensor data 207 and / or control and / or regulation data, for the manufacturing process 200. The subsequent process data 212 comprise in particular a target subsequent parameter set with one or more subsequent process parameters 212.1 of target machine data of the extrusion device 10, in particular in the form of control and / or regulation data for the subsequent process 210. Furthermore, the process data 202 and the subsequent process data 212 comprise in particular material data.

[0058] It can be provided that several orders are present in a process collection 240 for the production of different film materials 211, which are to be processed after the production of the first film material 201. In order to make the process change as efficient as possible, the subsequent process 210 can preferably first be determined 103 based on the process collection 240 by analyzing the process collection 240 based on the process data 202 and the subsequent process data 212. During the analysis, it can be determined, for example, which of the production processes 200.1 planned according to the process collection 240 requires the least adjustment and / or has the greatest agreement with the ongoing production process 200. The process collection 240 can be stored in a memory unit 21 of the control system 20.

[0059] Depending on the process data 202 and the subsequent process data 212, a prediction 104 of at least one material flow 225 within the extrusion device 10 for the process change is further carried out. The material flow 225 is shown in Figures 2a and 2b within the extrusion device 10. The material flow 225 can be calculated, for example, using a calculation model 253 for a material distribution and / or a material movement in the extrusion device 10. Thus, the manufacturing process 200 and / or the process change can be mapped and / or predicted with high accuracy using the material flow 225.

[0060] Furthermore, at least one preparatory measure 230 is executed 105 to trigger at least one event 237 of the process change depending on the material flow 225. As shown in Figure 1, the preparatory measure 230 comprises, in particular, an automatic control 232.2 of the extrusion device 10 and / or an output of a recommended action 232.1 for execution 105 by an operator. The extrusion device 10 can be controlled by control data of the control system 20 in order to implement the automatic control 232.2. The recommended action 232.1 can be visualized for an operator, for example, by a display device 22 of the control system 20. In particular, the event 237 can be triggered by the execution 105 of the preparatory measure 230 at an event location 238 of the extrusion device 10.The execution 105 of the preparatory measure 230 is, in particular, temporally coordinated with the material flow 225, so that the material flow 225 correlates temporally with the event 237 at the event location 238. Furthermore, the preparatory measure 230 is preferably determined as a function of a predetermined, in particular to be optimized, target variable 208 for the transfer of the extrusion device 10. The target variable 208 can be, for example, a material quantity, a changeover time for the process change, a quality criterion for the first film material 201 and / or the second film material 211, and / or a process reliability when carrying out the process change.

[0061] For example, the material flow 225 can comprise a movement of a material in the extrusion device 10 up to the event location 238, and the event 237 can comprise reaching a target value of a process parameter 202.1. Thus, Figure 2a shows that, through a preparatory measure 230, an adjustment 236.2 of a temperature of an extruder 11 of the extrusion device 10 is coordinated with the material flow 225 of a material ingredient 206 in such a way that a predetermined temperature value is reached when the material ingredient 206 arrives at the event location 238. As a result, the predetermined temperature value can be reached at a late point in time in order to make the process change as sharp as possible.Furthermore, as shown in the synopsis of Figures 2a and 2b, a material change can be carried out, for example, at a feed device 12 of the extrusion device 10 while a good production of the first film material 201 is still being output at the film blowing head 14 during the production process 200. For this purpose, a balance 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 calculated. For example, a process completion 204 of the production process 200 can be predicted depending on the material flow 225 for a point in time in the future during the balance 224. Furthermore, the preparatory measure 230, as shown in Figure 3, can comprise several change processes 236 for executing the process change. For example, the preparatory measure 230 can be a change in a material supply 12.1, a change 236.3 of the process data 202 for maintaining bubble stability of a film bubble, in particular during the temperature adjustment 236.2, and / or a start process for the intermediate process 200.3 for producing an intermediate material. The change processes 236 can be prioritized and / or output sequentially when performing the preparatory measure 230 in order to guide the process change.

[0062] Furthermore, the preparatory measure 230 can comprise a rinsing process 236.1 of at least part of the extrusion device 10. In this case, the material flow 225 for a rinsing material of the rinsing process 236.1 can be determined. Depending on the process data 202 and the material flow 225, a rinsing time of the rinsing process 236.1 is also calculated in order to execute the preparatory measure 230 as a function of the rinsing time. As a result, the rinsing process 236.1 can, for example, already be completed in the area of ​​the feed devices 12, while at the film blowing head 14, the completion of the rinsing process 236.1 cannot yet be detected, e.g., due to residual particles and / or streaking.

[0063] As further shown in Figure 3, the preparatory measure 230 can be determined based on a recording of a reference change 251, which preferably maps a process change from the process data 202 to the subsequent process data 212. For example, to record the reference change 251, an experienced operator can perform and record several change actions so that subsequent operators can benefit from the experience of the experienced operator and be guided through the process change with the preparatory measure 230. Based on the material flow 225, it can be determined when the preparatory measure 230 should take place. Furthermore, it is conceivable that the preparatory measure 230 is determined differently from a change action of the reference change 251 if the calculated material flow 225 deviates from the reference change 251.

[0064] Furthermore, it can be provided that sensor data 207, in particular from one or more sensors 13 of the extrusion device 10, is recorded 106 to detect a change in the manufacturing process 200 that occurs as a function of the preparatory measure 230. In this case, the sensor data 207 are preferably monitored with respect to the target variable 208. This allows errors during the process change to be identified. Furthermore, the determination of the material flow 225 can be updated as a function of the sensor data 207 in order to react dynamically to changed process conditions.

[0065] In addition or alternatively to the reference change 251, it can be provided that the material flow 225 and / or the preparatory measure 230 is determined based on a process history 250 of previous manufacturing processes 200.2. The process history 250 can, for example, be part of a database and include execution data 252, in particular with sensor data 207, of the previous manufacturing processes 200.2. Based on the execution data 252 of the process history 250, conclusions can be drawn about the current process change. In order to create a self-learning system 1, execution data 252 of the preparatory measure 230 of the current process change, preferably depending on the sensor data 207, can be stored as part of the process history 250 for provision for further subsequent processes 210.In particular, the control unit 23 can have an artificial intelligence 24, to which the process data 202 and the subsequent process data 212 are fed as input data in order to obtain the material flow 225 and / or the preparatory measure 230 as output data. Additionally or alternatively, the execution data 252 and / or the process history 250 with the sensor data 207, the process data 202, and / or the subsequent process data 212 can be fed to the artificial intelligence 24 as training data.

[0066] The above explanation of the embodiments describes the present invention exclusively within the framework of examples. Of course, individual features of the embodiments can be freely combined with one another, provided that they are technically expedient, without departing from the scope of the present invention. Reference symbol list System Extrusion device Device section Extruder Feed device Material supply Sensor Film blowing head Control system Storage unit Display device Control unit Artificial intelligence Method Detecting 202 Detecting 212 Determining 210 Predetermining 225 Executing 230 Detecting 207 Manufacturing process Planned manufacturing process Previous manufacturing process Intermediate process First film material Material sections Process data Process parameter set Process completion

[0067] Material ingredient

[0068] Sensor data

[0069] Target size

[0070] Subsequent process second film material of different film materials

[0071] Follow-up process data

[0072] Subsequent process parameter set

[0073] Accounting

[0074] Material flow

[0075] Preparatory measure

[0076] Recommendation for action

[0077] Control

[0078] Material change

[0079] Exchange transactions

[0080] Rinsing process

[0081] Adjusting a temperature

[0082] Amendment of 202 to maintain stability of the film bubble

[0083] Event

[0084] Event location

[0085] Process collection

[0086] Process history

[0087] Reference change

[0088] Implementation dates

[0089] Calculation model

Claims

Patent claims Method (100) for supporting the implementation of 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: - Recording (101) of process data (202) of the manufacturing process (200), - recording (102) of follow-up process data (212) of the follow-up process (210), - Predetermining (104) at least one material flow (225) within the extrusion device (10) for the process change depending on the process data (202) and the subsequent process data (212), - Executing (105) at least one preparatory measure (230) to trigger at least one event (237) of the process change depending on the material flow (225). The method (100) according to claim 1, characterized in that the preparatory measure (230) comprises an automatic control (232.2) of the extrusion device (10) and / or an output of a recommended action (232.1) for execution by an operator. The method (100) according to claim 1 or 2, characterized in that the predetermination (104) of the material flow (225) is carried out using a calculation model (253) for a material distribution and / or a material movement in the extrusion device (10).Method (100) according to one of the preceding claims, characterized in that the event (237) can be caused or is caused by the execution (105) of the preparatory measure (230) at an event location (238) of the extrusion device (10), and the execution (105) of the preparatory measure (230) is temporal. is coordinated with the material flow (225) so that the material flow (225) correlates in time with the event (237) at the event location (238). Method (100) according to one of the preceding claims, characterized in that the material flow (225) comprises a movement of a material in the extrusion device (10) up to the event location (238), wherein the event (237) comprises reaching a target value of a process parameter (202.1) at the event location (238). Method (100) according to one of the preceding claims, characterized in that the preparatory measure (230) at least partially comprises at least one of the following changeover processes (236): - Change of a material stock (12.1), - adjusting (236.2) a temperature of the extrusion device (10), - changing (236.3) the process data (202) to maintain bubble stability of a film bubble, in particular during the adjustment (236.2) of the temperature, - Starting process for an intermediate process (210.1) for producing an intermediate material. Method (100) according to one of the preceding claims, characterized in that the preparatory measure (230) comprises a plurality of change processes (236) for executing the process change, wherein the change processes (236) are prioritized and / or output sequentially when the preparatory measure (230) is carried out. Method (100) according to one of the preceding claims, characterized in that the preparatory measure (230) is determined based on a recording of a reference change (251), in particular from the process data (202) to the subsequent process data (212). Method (100) according to one of the preceding claims, characterized in that the preparatory measure (230) comprises a rinsing process (236.1) of at least part of the extrusion device (10), in particular wherein the material flow (225) comprises a movement of a rinsing material of the rinsing process (236.1). Method (100) according to one of the preceding claims, characterized in that a rinsing time of the rinsing process (236.1) is calculated as a function of the process data (202) and the material flow (225), wherein the preparatory measure (230) is carried out as a function of the rinsing time. Method (100) according to one of the preceding claims, characterized in that a process completion (204) of the manufacturing process (200) is calculated in advance as a function of the material flow (225), in particular wherein the event (237) is assigned to the process completion (204).Method (100) according to one of the preceding claims, characterized in that the preparatory measure (230) is determined as a function of a predetermined target variable (208) for the transfer of the extrusion device (10), in particular wherein the target variable (208) comprises a material quantity, a changeover time of the process change, a quality criterion for the first film material (201) and / or the second film material (211), and / or process reliability when carrying out the process change. 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) is carried out, in particular wherein the preparatory measure (230) and / or the calculation of the process completion (204) is carried out as a function of the balancing (224). Method (100) according to one of the preceding claims,. characterized in that the balancing (224) is carried out as a function of the predetermination (104) of the material flow (225) for a point in time in the future during the balancing (224). Method (100) according to one of the preceding claims, characterized in that the method (100) comprises: Acquiring (106) sensor data (207) for detecting a change in the manufacturing process (200) that occurs as a function of the preparatory measure (230), in particular wherein the sensor data (207) are monitored with regard to the target variable (208) and / or the determination of the material flow (225) is updated as a function of the sensor data (207). Method (100) according to one of the preceding claims, characterized in that the material flow (225) and / or the preparatory measure (230) is determined based on a process history (250) of previous manufacturing processes (200.1), in particular wherein implementation data (252) of the preparatory measure (230), preferably as a function of the sensor data (207), is stored as part of the process history (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 data (202) and the subsequent process data (212) are fed as input data in order to obtain the material flow (225) and / or the preparatory measure (230) as output data, and / or that the implementation data (252) and / or the process history (250) with the sensor data (207), the process data (202) and / or the subsequent process data (212) are fed to the artificial intelligence (24) as training data. Method (100) according to one of the preceding claims, characterized in that. that the method (100) comprises: - Determining (103) the subsequent process (210) based on a process collection (240) for producing different film materials (211) by analyzing the process collection (240) based on the process data (202) and the subsequent process data (212). 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 one of the preceding claims. A system (1) 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 one of claims 1 to 18.

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