Method for automatically determining consumption data of media in a filling line and device for carrying out the method
Patent Information
- Application Number
- EP2023768228
- Authority / Receiving Office
- EP · EP
- Patent Type
- Applications
- Current Assignee / Owner
- Priority Date
- 2022-09-08
- Filing Date
- 2023-09-06
- Publication Date
- 2025-07-16
AI Technical Summary
Current systems for monitoring media consumption in filling lines lack a comprehensive, cross-machine and system-wide display of consumption data, failing to provide timely alerts and optimize resource refilling/emptying across multiple machines and the entire production line.
A method and device for automatically determining media consumption data in a filling line, which involves determining the actual quantity and remaining time of media, transmitting this data to an external memory, creating a consumption monitor, and displaying it across machines and systems, taking into account context information such as production order progress, machine performance, and prioritization to ensure timely refilling or emptying of resources.
Enables a centralized and efficient monitoring of media consumption, allowing for proactive refilling or emptying of resources, preventing production stops and optimizing resource management by providing real-time data on actual quantities and remaining lifetimes of media across the filling line.
Smart Images
Figure 1.1
Abstract
Description
[0001] Method for automatically determining consumption data of media in a filling line and device for carrying out the method
[0002] The invention relates to a method for automatically determining consumption data of media in a filling line and a device for carrying out the method according to the independent claims.
[0003] State of the art
[0004] It is known to display a consumable material indicator for a machine in a filling line on a human-machine interface of the respective machine. A warning signal, for example in the form of a light, can be provided to indicate when the material is running low.
[0005] EP2815216 A1 discloses a device for providing consumables for a packaging machine, wherein the device comprises a magazine for the consumables and a detection device for determining an actual quantity of consumables in the magazine. The detection device can be coupled to a display unit, by means of which the actual quantity of consumables in the magazine can be displayed. The display unit can include a warning function with which a warning signal can be generated if the actual quantity falls below a predefined minimum quantity.
[0006] Task
[0007] The object of the invention is to provide a method for automatically determining consumption data of media in a filling line and a device for carrying out the method, which enables a cross-machine and cross-plant representation of consumption data of the media.
[0008] Solution
[0009] The object is achieved by the method for automatically determining consumption data of media in a filling line and a device for carrying out the method according to the independent claims. Further embodiments are disclosed in the subclaims.
[0010] A method for automatically determining consumption data of media in a filling line comprising at least one media-consuming machine, wherein the consumption data comprises an actual quantity and a remaining running time of the medium, comprises determining an actual quantity of a medium of the at least one machine, transmitting the actual quantity in a predetermined format via an edge device to an external memory, transmitting context information relating to the filling line and the at least one machine via the edge device to the external memory, creating a consumption monitor comprising the consumption data of the media within an external memory, determining a remaining running time of the medium based on the actual quantity of the medium and on context information relating to the filling line and the at least one machine, transmitting the consumption monitor to a display device,displaying the consumption monitor by means of the display device and using the consumption data when operating the filling line.
[0011] The actual quantity of the medium can be determined based on the fill level in a supply container. This can be the case, for example, with glue, which is provided in a glue container for use in a labeling machine on the filling line.
[0012] The actual quantity can be determined by comparing the originally provided quantity of medium with the quantity of medium already used, for example, during a production process in the filling line. This can be provided, for example, with the medium label.
[0013] The actual quantity can be determined by the number of ejected containers in a waste container and / or the fill level of the ejected containers in the waste container and / or by the weight of the waste container with the ejected containers in it compared to the empty waste container.
[0014] Since both the filling line and the machine consuming the medium can influence the consumption of the medium, not only the actual quantity of the medium is taken into account to determine the remaining running time of the medium, but also the context information concerning the filling line and the at least one machine.
[0015] The consumption data, which includes the actual quantity and the remaining lifespan of the medium, can be used during operation to ensure that a medium can be refilled (glue, labels, closures, clips, preforms) or emptied (capacity, for example of a waste container) in good time before the end of the remaining lifespan.
[0016] The at least one media-consuming machine may comprise a control unit. If there are multiple media-consuming machines, each of the machines may comprise a control unit. The control unit may be used to control the machine and may be configured, for example, as a computer with an associated processor and (internal) memory, as well as suitable programming.
[0017] The external memory can be located outside each control unit of the media-consuming machines. The external memory can therefore not be included in any of the control units. The external memory can be a data memory or include a data memory. The external memory can be accessed from outside the filling line and / or the machine. The actual quantity and context information can be further processed in the external memory.
[0018] The creation of a consumption monitor comprising the media consumption data takes place, for example, within an external storage device. This external storage device can be different from the external storage device mentioned above, or this external storage device can correspond to the external storage device mentioned above. If this external storage device is different from the external storage device mentioned above, it can also be provided that this external storage device can be located outside of each control unit of the media-consuming machines. This external storage device can therefore not be included in any of the control units.
[0019] Creation of the consumption monitor in a machine control system cannot be provided. This involves a method for automatically determining consumption data of media in a filling line, so that it may not be sufficient to consider the at least one media-consuming machine. In one embodiment, it is provided that the determination of the remaining running time of the medium is based on the actual quantity of the medium and on context information relating to the filling line. In addition to the at least one machine alone, the filling line as a whole can also be taken into account. Thus, it can be provided that the creation of the consumption monitor comprising the media consumption data can take place within the external memory.
[0020] By transmitting the consumption monitor to the display device and displaying the consumption monitor by means of the display device, the consumption data can be collected locally, the consumption monitor can be created within an external memory and can be transmitted back to the media-consuming machine for displaying the consumption monitor.
[0021] The context information may include at least one of:
[0022] - temporal progress of a production order in the filling line,
[0023] - historical filling line and / or machine performance for the production order,
[0024] - planned filling line and / or machine performance for the production order,
[0025] - Prioritization of at least one machine and / or medium in the production order,
[0026] - time required to fill / empty the medium,
[0027] - Type of production order, for example, the media required and / or the machines used in the filling line. The temporal progress of a production order in the filling line can be relevant to determine whether refilling / emptying of media is still required during this production order or whether the production order has already been completed before refilling / emptying would be necessary.
[0028] From the historical filling line and / or machine performance during the production order, conclusions can be drawn about the further behavior of the filling line and / or at least one machine at the same or different performance levels.
[0029] Media prioritization in a production order can be relevant to determining which media should be refilled first, for example, if two different media need to be refilled, to avoid a stoppage of the filling line. For example, prioritization can specify that labels should be refilled first, followed by clips.
[0030] The time required to fill / empty the medium can be relevant to determine when to start filling / emptying within the remaining lifetime to avoid running out of the medium.
[0031] For example, the nature of the production order may dictate that neck labels are not used. This can prevent unnecessary refilling of neck labels.
[0032] The media may include at least one of: preforms, labels, glue, clips, closures, film, cardboard, pallets, storage volume, for example in waste containers.
[0033] One of the at least one machine can use one medium or different media.
[0034] The consumption monitor can display media consumption data across all filling lines and machines. The consumption monitor can be accessed from outside the filling line and / or machine, as it can be created within the external memory.
[0035] The consumption monitor may further include at least one of:
[0036] - Name of at least one machine,
[0037] - Name of the medium consumed by the machine,
[0038] - Designation of a production order carried out in the filling line,
[0039] - Designation of a production order planned in the filling line,
[0040] - Identification of whether or not refilling / emptying of media is required during the production order being executed, - Identification of the time at which the consumption monitor was last updated.
[0041] The additional information provided by the consumption monitor allows a clear assignment between the machine, the medium consumed by the machine (one medium, several different media where refilling or emptying may be necessary) and the requirements for refilling / emptying the medium.
[0042] By naming the production order carried out in the filling line, conclusions can be drawn as to which media are required for it and, for example, how long the production order will last, assuming the planned filling line and / or machine performance, before it ends and, if necessary, a planned production order can begin.
[0043] The consumption monitor can include a separate display area for each medium for the medium's consumption data. The display area can show the machine, the actual quantity of the medium (e.g., in percent), and the remaining running time (e.g., in minutes). If the actual quantity is above a minimum value, the corresponding display area can be green, or the actual quantity and remaining running time can be green. The minimum value can be different for different media. The minimum value can vary depending on the filling line and / or machine performance, but it can also be independent of the filling line and / or machine performance. If the actual quantity of the medium falls below the minimum value, the corresponding display area can be orange, or the actual quantity and remaining running time can be orange.If the actual quantity is zero, the corresponding display area may be colored red, or the actual quantity and remaining runtime information may be colored red. For example, if the data connection to the machine is interrupted, the corresponding display area may be gray.
[0044] The minimum value can be a dynamic minimum value.
[0045] For the dynamic minimum value, at least one of the following can be considered:
[0046] - a position of an operator of the filling line or positions of several operators of the filling line, whereby, for example, the position of the operator can be determined by a mobile device and / or ID token and / or tablet and / or smartwatch assigned to the operator,
[0047] - a number of operators of the filling plant,
[0048] - the availability of one or more operators of the filling plant, - the actual quantity of the medium is such that the remaining time for filling or emptying is such that continuous operation of the filling line is ensured,
[0049] - an average time for filling or emptying.
[0050] For example, the dynamic minimum value may be smaller if the operator is closer to the corresponding media-consuming machine. For example, the dynamic minimum value may be larger if the operator is farther away from the corresponding media-consuming machine. A dynamic change from a first minimum value to a smaller, second minimum value may occur if the operator's position changes and they move closer to the corresponding machine. A dynamic change from a third minimum value to a larger, fourth minimum value may occur if the operator's position changes and they move away from the corresponding machine.
[0051] Closer to or farther from the respective machine can mean the distance the operator must travel in the filling line. For a longer distance, the dynamic minimum value can be higher than for a shorter distance. Generally, the distance to be traveled cannot be equal to the straight-line distance.
[0052] The method may include calculating the minimum value / the dynamic minimum value. For example, the minimum value may be calculated in one of the aforementioned external memories.
[0053] The display can be done via a central control station, such as a dashboard, and / or via a mobile device, such as a smartphone, laptop, and / or tablet. The central control station can be located in a hall where the filling line is located. The mobile device can be operated by an operator whose responsibility may include one or more machines on the filling line. Additionally or alternatively, the consumption monitor can be displayed on the HMI (Human Machine Interface) of a machine that may be located within the filling line. For example, displaying it on the HMI of a machine within the area of responsibility of an operator can be advantageous.For example, the consumption monitor displayed to the operator on their mobile device can be additionally or alternatively displayed on an HMI if the operator is within the operating and / or visual range of the HMI of one of the machines. The display of the corresponding consumption monitor on the HMI can be started manually or automatically. Manually, for example, through manual intervention by the operator on the mobile device (by issuing the command to transfer / mirror the consumption monitor to the HMI); automatically, for example, through the operator approaching an HMI, whereby the approach can be detected by knowing the operator's position in the hall. The position in the hall can be determined, for example, using GPS data, sensors, and / or cameras.
[0054] A notification can be sent to a mobile device, such as a smartphone, laptop, and / or tablet, when the actual quantity and / or the remaining runtime fall below a respective minimum value. An operator located outside the filling line and / or outside a hall containing the filling line can be informed about the need to refill / empty a medium. The properties already described above in connection with the minimum value and the dynamic minimum value can apply to the respective minimum value. For example, the respective minimum values can be dynamic minimum values.
[0055] The notification may include instructions for filling / emptying the medium. The instructions may include information on the time required for filling / emptying and / or information on how the filling / emptying is to be carried out.
[0056] The consumption monitor can be created for a selection of at least one machine based on responsibility data. For example, if an operator is only responsible for one of the at least one machines, it may be sufficient to provide the operator with access to a consumption monitor that only applies to that specific machine.
[0057] The responsibility data may include the responsibility of an operator. The operator may be responsible for one or more of the at least one machine on the filling line.
[0058] Determining responsibility data can be based on an operator's identity using time clock data. Data recorded by the time clock can be made accessible or accessible.
[0059] An apparatus for carrying out the method as described above or further below is provided.
[0060] Short character description
[0061] The attached figures represent aspects and / or embodiments of the invention by way of example for better understanding and illustration. It shows:
[0062] Figure 1 is a block diagram to explain part of the method and
[0063] Figure 2 shows a schematic consumption monitor.
[0064] Detailed description of the figures Figure 1 shows a block diagram to explain part of the method as described above. A filling line 1 comprises, by way of example, three media-consuming machines 2, 4, 7. The first machine 2 consumes a first medium 3, the second machine 4 consumes a second medium 5 and a third medium 6, and the third machine 7 consumes a fourth medium 8 and a fifth medium 9. The actual quantities 26 of the various media 3, 5, 6, 8, 9 can be determined. For the first medium, a first actual quantity 27 can result, for the second medium 5 a second actual quantity 28, for the third medium 6 a third actual quantity 29, for the fourth medium 8 a fourth actual quantity 30, and for the fifth medium 9 a fifth actual quantity 31.
[0065] The remaining running times of the media 3, 5, 6, 8, 9 can be determined based on the respective actual quantity 27, 28, 29, 30, 31 of the medium 3, 5, 6, 8, 9 and on context information 10 concerning the filling line 1 and the machines 2, 4, 7.
[0066] The context information 10 can include current data 11 and planned data 12 of the filling line 1, current data 13 and planned data 14 of the first machine 2, current data 15 and planned data 16 of the second machine 4 and current data 17 and planned data 18 of the third machine 7.
[0067] In addition, the context information 10 can include historical data 19 of the filling line 1, historical data 20 of the first machine 2, historical data of the second machine 4 and historical data of the third machine 7.
[0068] Furthermore, the context information 10 may include prioritization data 23 relating to the first machine 2, prioritization data 24 relating to the second machine 4 and prioritization data 25 relating to the third machine 7.
[0069] Remaining runtimes 32 of the medium can be determined based on the respective actual quantity 27, 28, 29, 30, 31 of the medium 3, 5, 6, 8, 9 and on context information 10 concerning the filling line 1 and the machines 2, 4, 7. A first remaining runtime 33 can result for the first medium 3, a second remaining runtime 34 for the second medium 5, a third remaining runtime 35 for the third medium 6, a fourth remaining runtime 36 for the fourth medium 8, and a fifth remaining runtime 37 for the fifth medium 9.
[0070] Figure 2 shows a schematic consumption monitor 38. It is understood that the illustrations and / or text provided here are merely examples, and other arrangements and configurations are also conceivable. Therefore, the displayed values for consumption and the like are merely examples and do not limit the invention. A first sub-area 39 indicates the media that may need to be refilled, and a second sub-area 40 indicates the media that may need to be emptied.
[0071] A first machine 41 consumes a first medium 42. Its actual quantity is indicated as 48% as numerical value 43 and is also marked as range 44. The remaining runtime 45 is indicated as 55:39 minutes. The actual quantity is above a minimum value, so there is no marking indicating a required refill.
[0072] A second machine 46 consumes a second medium 47. Its actual quantity is indicated as 13% by the numerical value 48 and is also marked as a range 49. The remaining runtime 50 is indicated as 20:54 minutes. The actual quantity is below a minimum value, so a marking 51—here, a double underline of the numerical value 48—is present because refilling is required. However, as can be seen from a first reading 60 of the consumption monitor 38, production will end in 20 minutes, and as can be seen from a second reading 61, refilling is not necessary. The remaining runtime 50 of the second medium 47 is greater than the time until production ends.
[0073] A third machine 52 consumes a third medium 53. Its actual quantity is indicated as numerical value 54, which is 86%, and is also marked as range 55. The actual quantity indicates, for example, the fill level of a waste container. The remaining runtime 56 is indicated as 15:00 minutes. A marking 57—here, double-underlined numerical value 54—is present because it requires emptying.
[0074] The consumption monitor 38 provides third information 58 on the current production and fourth information 59 on the planned production, with the type of bottle being given as an example.
Claims
Claims 1. A method for automatically determining consumption data of media (3, 5, 6, 8, 9, 42, 47, 53) in a filling line (1) comprising at least one media-consuming machine (2, 4, 7, 41, 46, 52), wherein the consumption data comprise an actual quantity (27, 28, 29, 30, 31) and a remaining running time (33, 34, 35, 36, 37, 45, 50, 56) of the medium (3, 5, 6, 8, 9, 42, 47, 53), the method comprising: - determining an actual quantity (27, 28, 29, 30, 31) of a medium (3, 5, 6, 8, 9, 42, 47, 53) of the at least one machine (2, 4, 7, 41, 46, 52), - Transmission of the actual quantity (27, 28, 29, 30, 31) in a specified format via an edge device to an external storage device, - transmitting context information (10) relating to the filling line and the at least one machine (2, 4, 7, 41, 46, 52) via the edge device to the external memory, - Creating a consumption monitor comprising the consumption data of the media (3, 5, 6, 8, 9, 42, 47, 53) within an external storage, - determining a remaining running time (33, 34, 35, 36, 37, 45, 50, 56) of the medium (3, 5, 6, 8, 9, 42, 47, 53) based on the actual quantity (27, 28, 29, 30, 31) of the medium (3, 5, 6, 8, 9, 42, 47, 53) and on the context information (10) relating to the filling line and the at least one machine (2, 4, 7, 41, 46, 52), - Transmitting the consumption monitor to a display device, - Displaying the consumption monitor using the display device and - Using the consumption data when operating the filling line (1).
2. The method of claim 1, wherein the context information comprises at least one of: - temporal progress of a production order in the filling line, - historical filling line and / or machine performance for the production order, - planned filling line and / or machine performance for the production order, - Prioritization of at least one machine (2, 4, 7, 41, 46, 52) and / or the medium (3, 5, 6, 8, 9, 42, 47, 53) in the production order, - time required to fill / empty the medium (3, 5, 6, 8, 9, 42, 47, 53), - Type of production order, for example media required (3, 5, 6, 8, 9, 42, 47, 53) and / or machines used (2, 4, 7, 41, 46, 52) in the filling line.
3. The method according to claim 1 or 2, wherein the media (3, 5, 6, 8, 9, 42, 47, 53) comprise at least one of: - preforms, - labels, - glue, - Clips, - closures, - foil, - cardboard, - pallets, - Capacity, for example in waste containers.
4. The method according to any one of claims 1 to 3, wherein the consumption monitor further comprises at least one of: - Designation of at least one machine (2, 4, 7, 41, 46, 52), - Name of the medium (3, 5, 6, 8, 9, 42, 47, 53) consumed by the machine (2, 4, 7, 41, 46, 52), - Designation of a production order carried out in the filling line, - Designation of a production order planned in the filling line, - Identification of whether or not refilling / emptying of medium (3, 5, 6, 8, 9, 42, 47, 53) is required during the production order being executed, - Specify the time at which the consumption monitor was last updated.
5. The method according to one of claims 1 to 4, wherein the consumption monitor for each medium (3, 5, 6, 8, 9, 42, 47, 53) comprises a respective display area for the consumption data of the medium (3, 5, 6, 8, 9, 42, 47, 53).
6. The method according to one of claims 1 to 5, wherein the display is carried out by means of a central control station, for example a dashboard, and / or by means of a mobile terminal, for example a smartphone, laptop, and / or tablet.
7. The method according to one of claims 1 to 6, wherein a notification is sent to a mobile terminal, for example a smartphone, laptop, and / or tablet, when the actual quantity (27, 28, 29, 30, 31) and / or the remaining term (33, 34, 35, 36, 37, 45, 50, 56) fall below a respective minimum value.
8. The method according to claim 7, wherein the notification comprises instructions for filling / emptying the medium (3, 5, 6, 8, 9, 42, 47, 53).
9. The method of claim 7 or 8, wherein the minimum value is a dynamic minimum value.
10. The method according to claim 9, wherein for the dynamic minimum value at least one of the following is taken into account: - a position of an operator of the filling line or positions of several operators of the filling line, whereby, for example, the position of the operator can be determined by a mobile device and / or ID token and / or tablet and / or smartwatch assigned to the operator, - a number of operators of the filling plant, - availability of one or more operators of the filling plant, - the actual quantity of the medium is such that the remaining time for filling or emptying is such that continuous operation of the filling line is ensured, - an average time for filling or emptying.
11. The method according to claim 9 or 10, further comprising calculating the minimum value or the dynamic minimum value, for example, wherein the calculation is performed in an external memory.
12. The method according to one of claims 1 to 11, wherein the consumption monitor is created for a selection of the at least one machine (2, 4, 7, 41, 46, 52) based on responsibility data.
13. The method of claim 12, wherein the responsibility data comprises a responsibility of an operator.
14. The method according to claim 12 or 13, wherein the responsibility data is determined based on an identity of an operator using recording data from a time clock.
15. Apparatus for carrying out the method according to one of claims 1 to 14.