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

Abstract

The invention relates to a method (100) for supporting at least one 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 a process change, computer program product and system

[0002] Description

[0003] The invention relates to a method for supporting a process change, 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 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] DE 10 2015 108 974 A1 therefore discloses the ability to predetermine a process limit in the form of the end of a production order and, in anticipation of this end of the production order, to specify a reduced changeover fill level. This can reduce material waste due to excess material during a process changeover. However, it is desirable to further reduce material waste.

[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 improve a process changeover of an extrusion device in order to shorten the required changeover time and / or reduce material waste during the process changeover.

[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 is provided for supporting at least one 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:

[0010] - Controlling the extrusion device to carry out the manufacturing process with at least one process parameter set, in particular by a control system, detecting at least one target subsequent parameter set of the subsequent process assigned to the process parameter set, in particular by the control system,

[0011] - Planning a preparatory process for preparing the subsequent process with at least one preparatory measure for at least partial or complete adaptation of the process parameter set depending on the assigned target subsequent parameter set, in particular by the control system, carrying out the preparatory measure during the manufacturing process in order to prepare the process change from the manufacturing process to the subsequent process, 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 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, of 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 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 target subsequent parameter set can comprise one or more subsequent process parameters from 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 subsequent process parameters that are assigned to the one or more process parameters of the process parameter set, but relate to the subsequent process. Upon detection of 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.

[0017] The preparatory process can comprise a chronological sequence of the manufacturing process, in particular the control of the extrusion device, up to the completion of the manufacturing process. For at least one process parameter, preferably for each process parameter, of the process parameter set, it can be determined whether and / or when the at least partial adaptation to the respectively assigned subsequent parameter of the subsequent parameter set takes place. However, it is also conceivable that only the, in particular the next, preparatory measure is defined when planning the preparatory process. In this case, the planning of the preparatory process can preferably be repeated after the preparatory measure has been carried out.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 subsequent process parameters of the target subsequent parameter set. Preferably, the influence of the adaptation on the manufacturing process is evaluated during the preparation process, and the preparation measure is determined depending on the influence of the adaptation on the manufacturing process. For example, the adaptation can be varied in order to optimize the preparation process, particularly with regard to the influence of the adaptation on the manufacturing process.Preferably, the planning of the preparation process is carried out 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 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, 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.

[0018] The preparatory measure is preferably defined during the preparatory process and / or executed automatically depending on the planned preparatory process. In particular, the preparatory measure is carried out during the manufacturing process, i.e. before the process change and / or the process completion of the manufacturing process. The preparatory measure can be designed to automatically execute and / or support the at least partial adaptation of the process parameter set to the target subsequent parameter set. It is conceivable that the preparatory measure comprises the output of one or more recommended actions for at least partially adapting the process parameter set to the assigned target subsequent parameter set. It has been recognized within the scope of the invention that certain measures for preparing the subsequent process can already be carried out during the manufacturing process, i.e.before the end of the manufacturing process, without impairing the manufacturing process. For example, it can be provided that in the subsequent process an increased temperature of a component of the extrusion device is required in order to produce the second film material, but an increase in the temperature, in particular within a certain range, still leads to a desired film quality of the first film material. Thus, suitable process parameters for adjustment during the manufacturing process can be identified during the preparation process. The extrusion device can be permanently controlled to carry out the manufacturing process. Therefore, the preparation process is planned and the preparatory measure is carried out, in particular, still during the manufacturing process.This blurs the boundary between the manufacturing process and the subsequent process and / or partially relocates it into the manufacturing process. If the preparation is carried out at least partially during the ongoing manufacturing process, during which the first film material is still being produced, material waste during process changeovers can be reduced and / or changeover times can be shortened.

[0019] It is further conceivable in a method according to the invention that, when planning the preparation process for the process parameter set of the manufacturing process, a limit parameter set is determined to limit the adaptation of the process parameter set. The limit parameter set can be defined, for example, based on a quality criterion for the first film material. In this case, a limit parameter and / or a limit range can preferably be specified for each process parameter. The limit parameter set can be determined when planning the preparation process. For example, the limit parameter set can be provided and / or retrieved from a storage unit. However, it is also conceivable that the limit parameter set is calculated, for example, based on a calculation model for the extrusion device and / or the manufacturing process.The limit parameter set can ensure that the adjustment of the process parameter set defined during planning of the preparation process has no effect, or only a minor effect, on the film quality of the first film material during the production process. Furthermore, in a method according to the invention, it is conceivable for the process parameter set to 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, the adjustment of which is determined during the preparation process. Setting a specific process temperature for the subsequent process generally requires a specific lead time to heat up a component of the extrusion device, such as a film blowing head. For example, a temperature adjustment rate can be operated at less than or equal to 20 °C per hour.At the same time, the manufacturing process can be insensitive to a difference in process temperature of a few degrees, so that good production is still possible during heating. By shifting the heating into the manufacturing process, the process boundary between the manufacturing process and the subsequent process can become blurred. Adjusting material feed data can, for example, have a positive effect on bubble stability if the manufacturing process involves blown film extrusion. The material feed data can therefore compensate for any negative effects of adjusting another process parameter. Furthermore, adjusting the material feed data can be used to prepare for a purging process for one or more extruders in the extrusion device.

[0020] Within the scope of the invention, it is further conceivable that, when planning the preparatory process, a process completion of the manufacturing process is calculated in advance as a function of the process parameter set, in particular wherein the implementation of the preparatory measure takes place in time as a function of the process completion. The process completion can be understood as a point, in particular a point in time, for the manufacturing process from which good production of the first film material is completed. After the process completion, the changeover process and / or the subsequent process can begin. Order data of the manufacturing process can be taken into account for the advance calculation of the process completion. Furthermore, a quantity of the first film material already produced by the manufacturing process can be determined for the advance calculation of the process completion. By calculating the process completion in advance, the timing for the adjustment can be improved.For example, a time point for the preparatory measure can be specified so that the completion of the adjustment of the process parameter set coincides with the completion of the process in terms of time and / or material consumption.

[0021] Furthermore, in a method according to the invention, it is conceivable that the method, in particular in the form of a method step, comprises:

[0022] Determining a process objective of the manufacturing process for producing the first film material, in particular by the control system, wherein the process completion is predicted depending on the process objective and the at least partial adaptation of the process parameter set. The process objective can, for example, comprise a quantity of the first film material to be produced. Furthermore, the process objective can have a correlation to one or more quality criteria of the first film material and / or a process stability of the manufacturing process. Thus, it is conceivable that the process objective comprises a specific quantity of a first film quality and a specific quantity of a second film quality of the first film material. The quantity of the first film material can, for example, be specified in weight and / or in produced rolls. Material data of the manufacturing process for producing the first film is preferably recorded to identify the process parameter set.The material data can include input data of a raw material and / or output data of a produced quantity of the first film material. Furthermore, the material data can include a material type, a material composition, in particular with percentages of material ingredients, and / or material properties, such as a viscosity of the material ingredients. Material ingredients can be understood, in particular, as raw materials of the manufacturing process. By comparing the process parameter set with the target subsequent parameter set, the process completion can be predicted for each order. When predicting the process completion, the remaining course of the manufacturing process can thus be included with the adjustment of the process parameter set.

[0023] Furthermore, it is conceivable within the scope of the invention 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 planning of the preparation process is carried out as a function of the material flow. When determining 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 certain 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 asa rinsing process, are required 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. 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 that 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. The material progression can thus be simulated in particular in order to at least partially calculate in advance whether the process goal will be achieved. This allows the comparison data and / or the recommended action to be prepared in an improved manner.

[0024] Within the scope of the invention, it is further conceivable that the preparatory measure comprises automatic control of the extrusion device for carrying out the at least partial adaptation of the process parameter set during the production process, i.e. in particular before the end of the process. During automatic control as a function of the preparatory process, a signal for controlling and / or regulating the extrusion device for the production process can be sent from the control system to the extrusion device. The control signal can comprise the adaptation 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 achieve a high level of precision in adapting the process parameter set. In addition, a time period can be created for an operator, which the operator can use to carry out further preparatory measures, such asmaterial procurement.

[0025] It is further conceivable in a method according to the invention that, in preparation for the completion of the process, i.e. in particular during the manufacturing process and / or before and / or when carrying out the preparatory measure, an automatic change in a material inflow to at least one extruder and / or a feed device of the extrusion device is carried out, in particular as a function of the completion of the process. When changing the material inflow, a material inflow of a first material ingredient of the manufacturing process can be reduced so that no or only a reduced amount of the first material ingredient is present in the extrusion device at the end of the process. Preferably, when changing the material inflow, the material inflow of the first material ingredient of the manufacturing process can be interrupted and / or a material inflow of a second material ingredient of the subsequent process can be activated.Changing the material flow can result in only the material still in the extruder and / or the feed device being used in order to reduce material waste during process changes.

[0026] Furthermore, in a method according to the invention, it can advantageously be provided that a preferably external or internal balancing of a produced 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 preparation process 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 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, for example, be measured 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. For this purpose, the user can be prompted during the preparation process.Within the scope of the invention, it is further conceivable that, for the balancing purpose, an evaluation of material sections of the produced first film material is carried out with regard to a quality criterion of the first film material, and in order to predict the fulfillment of the process objective, it is checked which of the material sections fulfill the quality criterion. The material sections can relate to different phases of the manufacturing process. For example, the phases of the manufacturing process can include an initialization process of the manufacturing process, e.g., in the form of a start-up of the extrusion device and / or a production run. Furthermore, the material sections can be divided into batches of the first film material. To evaluate the quality criterion, a film quality of the first film material can preferably be measured.The quality criterion can include, for example, a relaxation value, a film thickness, a print quality of an imprint on the first film material, and / or a transparency of the produced first film material. Furthermore, when evaluating the material sections, local deviations from the quality criterion in the form of irregularities in the manufacturing process and / or in the first film material can be identified. The irregularities can be eliminated during the balancing process. By evaluating the material sections, it can be ensured that only material sections that meet the quality criterion are included in the balancing process. This allows a differentiated overview of the quantity of first film material produced to be obtained in order to meet the process objective and plan the preparation process.

[0027] Preferably, in a method according to the invention, it can advantageously be provided that, preferably for planning the preparatory process and / or for determining the preparatory measure, a process turning point is determined based on the balancing and / or on the completion of the process, beyond which a continuation of the manufacturing process while maintaining a quality criterion and / or a process stability criterion of the first film material is no longer possible. The quality criterion can be the quality criterion of the material sections. Preferably, after the process turning point, the process change to the subsequent process is 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 after the process turning point, in particular electronically.The process turning point can be output as information to an operator. In particular, the process turning point can prevent, for example, poor production from occurring unnoticed due to manual user interaction during the manufacturing process, which then reverts to good production due to a subsequent extension of the manufacturing process. Furthermore, it can be stipulated that confirmation of the process turning point by 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, particularly through the preparatory measure.

[0028] Within the scope of the invention, it is further conceivable that the method comprises:

[0029] 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, wherein the sensor data are monitored with regard to a process condition of the manufacturing process, in particular wherein the process condition comprises the quality criterion of the first film material and / or a process stability criterion of the manufacturing process. Preferably, the preparatory measure is interrupted and / or a countermeasure is implemented if it is determined from the sensor data that the process condition 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 can include maintaining a bubble shape to prevent film tear and thus an interruption of the manufacturing process. Thus, the sensor data can be used for monitoring to control the influence of the preparatory measure on the manufacturing process.

[0030] Preferably, a method according to the invention can be provided that the method comprises:

[0031] Determining the subsequent process based on a process collection for producing different film materials by analyzing the process collection based on the process parameter set of the manufacturing process with a view to at least partially adapting the process parameter set.

[0032] In particular, a target variable for determining the subsequent 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 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 manufactured. 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 the process changeover. When analyzing the process collection, a parameter comparison of the process parameter set of the ongoing manufacturing process with parameter sets of the planned manufacturing processes can be carried out.For example, the recipes of the planned manufacturing processes can be checked during the prioritization process for their similarity to the recipe of the ongoing manufacturing process. Furthermore, the process collection can be sorted to determine the subsequent process and establish a sequence of the manufacturing processes. By determining the subsequent process based on the process collection, material waste and / or the complexity of the process change for the operator can be reduced during the process change, especially if the greatest possible similarity is achieved between the manufacturing process and the subsequent process.

[0033] Within the scope of the invention, it is further conceivable that reference data of at least one reference change and / or a process history of previous manufacturing processes are provided for the ongoing manufacturing process, wherein the planning of the preparation process and / or the calculation of the process completion is carried out depending on the reference data. 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 purposes 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 on the basis of the reference change to carry out the process change.The control system can preferably comprise artificial intelligence, particularly in the form of an artificial neural network. The reference data can serve as training data for the artificial intelligence. The process parameter set and the target follow-up parameter set can preferably be fed to the artificial intelligence as input data in order to obtain the planning of the preparation process and / or the preparation measure as output data. The reference data can provide an advantageous starting point for the preparation process, 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.

[0034] 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 stored with the implementation data, a system reaction to the preparatory measure can also be detected and evaluated. 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.

[0035] 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, and preferably the process goal, are fed as input data in order to obtain the planning of the preparatory process and / or the preparatory measure as output data, and / or that the implementation data and / or the process history with the sensor data, the process parameter set and the target subsequent parameter set, and preferably the process goal, 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. Additionally or alternatively, it is conceivable that the preparatory process is fed to the artificial intelligence as input data in order to obtain the preparatory measure as output data.Preferably, the control system, in particular a control unit of the control system, can comprise artificial intelligence, in particular in the form of an artificial neural network. Artificial intelligence can create a self-learning system. Furthermore, artificial intelligence can process large amounts of data to optimize process changeover.

[0036] 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.

[0037] 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.

[0038] 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.

[0039] 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.

[0040] 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:

[0041] Figure 1 shows a system according to the invention when carrying out a method according to the invention,

[0042] Figures 2a+b parts of an extrusion device of the system during a process change,

[0043] Figure 3 shows a process flow during the process change, and

[0044] Figure 4 Executions of preparatory measures for the process change, and

[0045] Figure 5 shows the method in a schematic representation of process steps. In the following description of some embodiments of the invention, identical reference numerals are used for the same technical features, even in different embodiments.

[0046] Figure 1 shows a system 1 according to the invention with an extrusion device 10 during the execution of a method 100 according to the invention for supporting 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.

[0047] 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 can be provided which comprises commands which, when executed by the control system 20, cause the control system 20 to carry out the method 100. Method steps of the method 100 are shown schematically in Figure 5. To carry out the manufacturing process 200, the method 100 first involves controlling 101 the extrusion device 10 with at least one process parameter set 202. The process parameter set 202 comprises, in particular, 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 process parameter set 202 can, in particular, be defined at least partially based on a recipe for the first film material 201.Preferably, a current status of the extrusion device 10 and the manufacturing process 200 is represented by the process parameter set 202. When the extrusion device 10 is controlled 101, the first film material 201 can be produced at least in sections.

[0048] Furthermore, the method 100 comprises a recognition 103 of at least one desired subsequent parameter set 212 of the subsequent process 210 assigned to the process parameter set 202. The desired subsequent parameter set 212 comprises in particular one or more subsequent process parameters 212.1 of desired machine data of the extrusion device 10, in particular in the form of control and / or regulation data, for the subsequent process 210. The process parameter set 202 can in particular be defined on the basis of a recipe for the second film material 211 and / or can be retrieved from a storage unit 21 of the control system 20 upon recognition 103 of the desired subsequent parameter set 212.

[0049] It can be provided that several orders are present in a process collection 240 for the production of different film materials, which orders 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 102 based on the process collection 240 by analyzing the process collection 240 based on the process parameter set 202 of the manufacturing process 200 with a view to at least partially adapting the process parameter set 202 during the process change. During the analysis, it can be determined, for example, which of the manufacturing processes 210.1 planned according to the process collection 240 requires the least adaptation and / or has the greatest agreement with the ongoing manufacturing process 200.Depending on the assigned target subsequent parameter set 212, the method 100 further includes planning 105 of a preparatory process 220 for preparing the subsequent process 210 for at least partially adapting the process parameter set 202. The preparatory process 220 is shown in Figure 3 and comprises at least one preparatory measure 230 for the at least partial adaptation of the process parameter set 202. The planning 105 of the preparatory process 220 extends from a part of the manufacturing process 200 to the start of the subsequent process 210. Various manual and / or automatic change actions 236 must be carried out in order to implement the process change. The preparatory measure 230 can, for example, B. at least one or more change actions 236 for a rinsing process 236.1, an adjustment 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 parameter set 202 for maintaining bubble stability of a film bubble, particularly during temperature adjustment. Furthermore, it is conceivable that the preparatory measure 230 includes a change in a material supply 12.1 and / or a start-up process for the intermediate process 200.3.

[0050] It has thus been recognized within the scope of the invention that some changeover actions 236 can already be carried out and / or prepared before the completion of the manufacturing process 200. For this purpose, at least one preparatory measure 230 for executing the preparatory process 220 for the process change can be defined during planning 105 of the preparatory process 220. In particular, the process parameter set 202 can be at least partially adapted to the associated target subsequent parameter set 212. Thus, it is conceivable that the process parameter set 202 comprises temperature data of the extrusion device 10 and / or material conveying data of the extrusion device 10, in particular in the form of a conveying speed and / or an extruder rotational speed, the adaptation of which is determined during the preparatory process 220.In particular, the fact that the production of film products and the implementation of recipes for the film products generally takes place within tolerances and / or depending on the interrelationships of the process parameters 202.1 is utilized. Therefore, the first film material 201 can continue to be produced even if individual process parameters 202.1 have already been changed. Therefore, during planning 105 of the preparation process 220 for the process parameter set 202 of the manufacturing process 200, a limit parameter set 222 is preferably determined to limit the adaptation to the target subsequent parameter set 212. The limit parameter set 222 can, for example, be taken from specified process data of the manufacturing process 200.

[0051] Furthermore, during planning 105 of the preparation process 220, a process completion 204 of the manufacturing process 200 is preferably calculated in advance depending on the process parameter set 202. This makes it possible, for example, to determine at what point in time the adjustment of the process parameter set 202 should be completed in order to begin the next phase of the process change and / or the subsequent process 210 after the adjustment. For this purpose, a process goal 205 of the manufacturing process 200 for producing the first film material 201 can first be determined 104. The process goal 205 can, for example, be determined based on order data for the manufacturing process

[0052] 200 can be detected. The process completion 204 can then be predicted depending on the process objective 205 and the at least partial adaptation of the process parameter set 202 to the associated target subsequent parameter set 212. In particular, the process completion 204 can be dynamically coordinated with the order-related boundary conditions in the form of the process objective 205 and / or the process-related planning of the adaptation of the process parameter set 202.

[0053] In order to be able to determine a current status of the manufacturing process 200 and / or to predict the process completion 204, the method 100 further includes a balancing 224 of a produced quantity of the first film material 201 and / or a quantity of a material ingredient 206 introduced into the extrusion device 10. As shown in Figures 2a and 2b, material data, in particular weight data, volume data, conveying data and / or the like, can be measured on the extrusion device 10 for this purpose. The balancing 224 is taken into account in particular during the planning 105 of the preparation process 220 in order to enable a timing of the adjustment and / or to define an optimal time for the adjustment.A product-related analysis of the balanced quantity can further be realized by evaluating material sections of the produced first film material 201 with regard to a quality criterion of the first film material for the balancing 224.

[0054] 201 takes place and, in order to predict whether the process target 205 is met, it is checked which of the material sections meet the quality criterion. For planning 105 the preparation process 220, a material flow 225 within the extrusion device 10 for the process change can also be determined depending on the process parameter set 202 and the target subsequent parameter set 212. For example, the material flow 225 can depict a movement of a material boundary between two successive raw materials 206 in the extrusion device 10. As a result, the process change can be at least partially material-controlled. In particular, for planning 105 a preparation process 220, a process turning point 209 is determined based on the balancing 224 and / or the process completion 204, from which point 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 by the display device 22.

[0055] As shown in Figure 3, reference data 223 of at least one reference change 251 for the ongoing manufacturing process 200 can also be provided. 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 comprise a recording of the reference change 251. Additionally or alternatively, the reference data 223 can comprise a process history 250 of previous manufacturing processes 200, which is retrieved from the storage unit 21. The planning 105 of the preparation process 220 and / or the calculation of the process completion 204 is carried out depending on the reference data 223.

[0056] As shown in Figure 4, depending on the preparation process 220, one or more preparation measures 230 are then carried out 106 in order to prepare the process change from the manufacturing process 200 to the subsequent process 210. The preparation measure 230 preferably comprises an automatic control 230.1 of the extrusion device 10 for carrying out the at least partial adaptation of the process parameter set 202 during the manufacturing process 200. Additionally or alternatively, it is conceivable that the preparation process 220 requires a user interaction 233 and the preparation measure 230 comprises an output of a recommended action 232 for carrying out the user interaction 233 to an operator, in particular via a display device 22 of the control system 20.The execution 106 of the preparatory measure 230 is preferably carried out in a temporally dependent manner on the process completion 204 in order to enable timing coordinated with the process completion 204. Furthermore, in preparation for the process completion 204, in particular before the execution 106 of the preparatory measure 230, an automatic change in a material flow to at least one extruder 11 and / or a feed device 12 of the extrusion device 10 can be carried out.

[0057] After or during the execution 106 of the preparatory measure 230, as shown in Figures 2a and 2b, sensor data 207 is acquired 107 to detect 103 a change in the manufacturing process 200 by one or more sensors 13 of the extrusion device 10 that occurs as a function of the preparatory measure 230. The sensor data 207 are monitored with respect to a process condition 208 of the manufacturing process 200. The process condition 208 includes the quality criterion of the first film material 201 and / or a process stability criterion of the manufacturing process 200.

[0058] In particular, depending on the sensor data 207, implementation data 252 of the preparatory measure 230 are preferably stored in the memory unit 22 of the control system 20, in particular as part of the process history 250 for provision for further subsequent processes 210, in order to achieve a learning effect and an improvement of the know-how, in particular internally, based on the implementation 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 fed as input data in order to obtain the planning of the preparatory process 220 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 parameter set 202 and the target follow-up parameter set 212 of the artificial intelligence 24 can be supplied to the artificial intelligence 24 as training data.

[0059] 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 feasible, without departing from the scope of the present invention. List of reference symbols

[0060] system

[0061] Extrusion device

[0062] Extruder

[0063] Feed device

[0064] sensor

[0065] Film blowing head

[0066] control system

[0067] storage unit

[0068] Display device

[0069] control unit

[0070] Proceedings

[0071] Control of 10

[0072] Determining 210

[0073] Recognizing 202

[0074] Determine 205

[0075] Plans of 220

[0076] Performing 230

[0077] manufacturing process planned manufacturing process previous manufacturing process

[0078] Intermediate process first film material

[0079] Process parameter set

[0080] Process parameters

[0081] Process completion

[0082] Process goal

[0083] Material ingredient

[0084] Sensor data Process condition Subsequent process Planned manufacturing process Second film material Intermediate material Target subsequent parameter set Subsequent process parameters Preparation process Limit parameter set Reference data Balancing Material flow Preparatory measure Recommended action User interaction Change action Flushing process Adjustment of a temperature Change of 202 to maintain stability of the film bubble Process collection Process history Reference change Implementation data

Claims

Patent claims Method (100) for supporting 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 an extrusion device (10), comprising: - controlling (101) the extrusion device (10) to carry out the manufacturing process (200) with at least one process parameter set (202), recognizing (103) at least one desired subsequent parameter set (212) of the subsequent process (210) associated with the process parameter set (202), - Planning (105) a preparatory process (220) for preparing the subsequent process (210) with at least one preparatory measure (230) for at least partially adapting the process parameter set (202) depending on the assigned target subsequent parameter set (212), Carrying out (106) the preparatory measure (230) during the manufacturing process (200) in order to prepare the process change from the manufacturing process (200) to the subsequent process (210). The method (100) according to claim 1, characterized in that, during the planning (105) of the preparatory process (220), a limit parameter set (222) for limiting the adjustment of the process parameter set (202) is determined for the process parameter set (202). The method (100) according to claim 1 or 2, characterized in that the process parameter set (202) comprises temperature data of the extrusion device (10) and / or material conveying data of the extrusion device (10), in particular in the form of a conveying speed and / or an extruder rotational speed, the adjustment of which is determined during the preparatory process (220). The method (100) according to one of the preceding claims, characterized in that that, during planning (105) of the preparation process (220), a process completion (204) of the manufacturing process (200) is precalculated depending on the process parameter set (202), in particular wherein the execution (106) of the preparation measure (230) takes place temporally dependent on the process completion (204). Method (100) according to one of the preceding claims, characterized in that the method (100) comprises: Determining (104) a process target (205) of the manufacturing process (200) for producing the first film material (201), wherein the process completion (204) is predicted as a function of the process target (205) and the at least partial adaptation of the process parameter set (202). 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 planning (105) of the preparation process (220) is carried out as a function of the material flow (225). Method (100) according to one of the preceding claims, characterized in that the preparatory measure (230) comprises an automatic control (230.1) of the extrusion device (10) for carrying out the at least partial adaptation of the process parameter set (202) during the manufacturing process (200).Method (100) according to one of the preceding claims, characterized in that in order to prepare for the completion of the process (204), in particular before carrying out the preparatory measure (230), an automatic change of a. Material inflow to at least one extruder (11) and / or a feed device (12) of the extrusion device (10). Method (100) according to one of the preceding claims, characterized in that a balancing (224) of a produced 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 preparation process (220) 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 for the balancing (224) an evaluation of material sections of the produced first film material (201) with regard to a quality criterion of the first film material (201) is carried out and, in order to predict the fulfillment of the process goal (205), it is checked which of the material sections fulfill the quality criterion.Method according to one of the preceding claims, characterized in that, for determining (105) the preparatory measure (230), a process turning point (209) is determined based on the balancing (224) and / or based on 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. Method (100) according to one of the preceding claims, characterized in that the method (100) comprises: Acquiring (107) sensor data (207) for detecting a change in the manufacturing process (200) which occurs as a function of the preparatory measure (230), wherein the sensor data (207) are monitored with regard to a process condition (208) of the manufacturing process (200), in particular wherein the process condition (208) comprises the quality criterion of the first film material (201) and / or a process stability criterion of the manufacturing process (200). Method (100) according to one of the preceding claims, characterized in that the method (100) comprises: Determining (102) the subsequent process (210) based on a process collection (240) for producing different film materials (211, 241) by analyzing the process collection (240) based on the process parameter set (202) of the manufacturing process (200) with regard to the at least partial adaptation of the process parameter set (202). Method (100) according to one of the preceding claims, characterized in that reference data (223) of at least one reference change (251) and / or a process history (250) of previous manufacturing processes (200.2) are provided for the ongoing manufacturing process (200), wherein the planning (105) of the preparatory process (220) and / or the calculation of the process completion (204) is carried out depending on the reference data (223).Method (100) according to one of the preceding claims, characterized in that implementation data (252) of the preparatory measure (230), in particular as a function of the sensor data (207), are 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 parameter set (202) and the target subsequent parameter set (212) are supplied as input data in order to obtain the planning of the preparatory process (220) and / or the preparatory measure (230) as output data, and / or that the implementation data (252) and / or the process history (250) are compared with the sensor data (207), the. Process parameter set (202) and the desired follow-up parameter set (212) are supplied to the artificial intelligence (24) as training data. A computer program product comprising instructions which, 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) 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 16.

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