Method for operating a production line

Abstract

The invention relates to a method for operating a production line that comprises a plurality of modules and in which food products are cut into slices, portions are formed in each case from one or more slices and the portions are packaged, and which comprises at least one cutting device, in particular a high-performance slicer, for cutting the products and for forming the portions, a packaging machine for packaging the portions, a transport section between the cutting device and the packaging machine for handling the portions, and a controller, wherein the production line furthermore comprises at least one sensor for monitoring at least one protective region associated with the production line, wherein the sensor provides sensor data concerning the monitoring for the controller, and wherein the controller, based on the provided sensor data, recognizes a specific situation in the protective region, assesses the recognized specific situation and adapts a movement of at least one module or of at least one component of a module of the production line on the basis of the result of the assessment.

Description

[0001] Method for operating a production line

[0002] The invention relates to a method for operating a production line comprising several modules, in which food products are cut into slices, portions are formed from one or more slices each, and the portions are packaged, and which comprises at least one slicing device, in particular a high-performance slicer, for slicing the products and forming the portions, a packaging machine for packaging the portions, a transport path for handling the portions between the slicing device and the packaging machine, and a control device.

[0003] The invention also relates to a production line in which food products are cut into slices, portions are formed from one or more slices each, and the portions are packaged, and which comprises at least one slicing device, in particular a high-performance slicer, for slicing the products and forming the portions, a packaging machine for packaging the portions, a transport path for handling the portions between the slicing device and the packaging machine, and a control device.

[0004] Such production lines and operating procedures for them are generally known in the relevant field of processing food products, in particular meat, sausage and cheese.

[0005] The modules of a production line of the type in question here usually contain moving parts that can pose a potential hazard to operators, but also to other modules or components of the line, or to external objects. Whether a particular movement poses a potential hazard or not can depend on the situation and the characteristics of the movement, such as the speed, the forces acting, or the sequence of the movement. Changing distances between line components due to the movement can also determine whether a situation exists that is to be considered a potentially hazardous condition or another condition requiring special measures.

[0006] Such special situations, which could pose a particular risk to persons or objects, can occur permanently in practice and thus particularly directly in the area of ​​the line. Alternatively or additionally, situations can occur in practice that only occur in phases. A component of a module or even just a part of a component can protrude permanently or in phases into the area surrounding the line, for example, to the side. This can temporarily endanger a walking path for operators or a travel path for automated conveyor vehicles, for example.

[0007] It is known to equip modules or components of modules with enclosures in order to protect objects, i.e. people and items that are not part of the line, from hazards. Such enclosures are typically equipped with sensors that monitor, for example, the positions of doors or other access devices. If such an enclosure is opened during operation or at another inadmissible time, the affected module or the entire line is stopped. Even if the shutdown occurs only in a single module, this can quickly lead to a standstill of the entire production line due to the functional interlinking of the modules that interact in the line, which is usually the case in practice. The high production speeds that have now been achieved on such lines are also problematic in this regard.These high speeds mean that in the event of a malfunction, for safety reasons and to maintain production when restarting the line, not only the affected module but the entire line must be shut down. Furthermore, after an interruption, an operator must confirm that a safe state has been restored so that the line can resume operation.

[0008] While the enclosures mentioned meet a high level of safety, they cannot be used on all modules because they are not flexible and require a lot of space. Labeling or printing devices used on packaging machines, for example, are particularly unsuitable for enclosures, as such devices are moved alongside the packaging machine during operation. To comply with applicable safety regulations, such labeling or printing devices can only be moved at certain speeds, and minimum clearances must also be maintained to avoid endangering operators.

[0009] In such facilities, efforts are made to avoid enclosures wherever possible, as these are extremely disadvantageous in terms of access and space requirements.

[0010] Regardless of the specific module of a production line affected, an interruption in operation always represents a disadvantage. Not only can it lead to uncertainty among the operating personnel, but an interruption always requires additional work steps by the operating personnel, who must ensure that the line resumes normal operation after an interruption. Another disadvantage is that interruptions in operation mean high mechanical stress, as such safety shutdowns usually occur abruptly, meaning that the affected components, which often have a large mass, must be braked suddenly. Particularly in the area of ​​food processing, interruptions in operation have the further disadvantage of increasing the time the food products spend in the line.Due to legal regulations, if the retention time is too long, it may be necessary to remove all food products from the line, i.e. clear the entire line, which creates waste. Even if this problem does not affect the entire line, efforts are made to avoid this type of waste. For example, waste can arise at a forming or sealing station on a packaging machine due to the thermal influences prevailing there. When the line is stopped, the products remain in the forming or sealing station for too long, so that they become overheated due to the temperatures prevailing in these stations, which can violate hygiene regulations. Another disadvantage of an excessively long retention time is that the films or other material used for the packaging can become unusable if they are heated for too long.

[0011] The object of the invention is therefore to improve a method and a production line of the type mentioned at the outset in such a way that the production line can be operated as efficiently as possible while providing maximum protection for persons and objects directly on the line and in its surroundings.

[0012] In the method according to the invention, it is provided that the production line further comprises at least one sensor for monitoring at least one protection area assigned to the production line, wherein the sensor provides sensor data relating to the monitoring to the control device, and wherein the control device detects a particular situation in the protection area on the basis of the sensor data provided, evaluates the detected particular situation and, depending on the result of the evaluation, adapts a movement of at least one module or at least one component of a module of the production line.In the production line according to the invention, it is provided that the production line further comprises at least one sensor for monitoring at least one protection area assigned to the production line, wherein the sensor is designed to provide sensor data relating to the monitoring to the control device, and wherein the control device is designed to detect a particular situation in the protection area on the basis of the provided sensor data, to evaluate the detected particular situation and, depending on the result of the evaluation, to adapt a movement of at least one module or at least one component of a module of the production line.

[0013] The invention is based on the idea that, in the event of a special situation that is considered, for example, a hazardous situation or another situation requiring some kind of action, the production line or part of it is not temporarily shut down or shut down as before, but rather the movement is adapted to the respective situation. For example, in a hazardous situation, the movement of one or more parts, for example, a module or a component of the module, can be slowed down.

[0014] Among other things, the invention is based on the realization that slow operation of the line can be advantageous for many reasons compared to even a temporary standstill of the line.

[0015] As already mentioned at the beginning, the special situation can in particular be a hazardous situation. In principle, other situations that require adaptation are also conceivable. The special situation can, for example, involve an object (a person, a body part of a person, an object belonging to the line or an external object) being in a place or position where this object does not belong. In particular, if the object is a person or a body part of a person, this special situation will generally be assessed as a hazardous situation. A special situation can also involve one or more components of the production line being in an improper position, or several components being, at least temporarily, not in their intended relative positions to one another.Such situations do not necessarily have to be considered hazardous situations, but can be considered disruptive or avoidable situations that require a specific measure. Such a measure, for example, the elimination of a malfunction, can be designed in such a way that a line shutdown is not required. Instead, it is sufficient to simply temporarily slow down the affected module or component, for example, without having to temporarily halt production of the module or the entire line.

[0016] A protection zone assigned to a specific sensor or multiple sensors can be an internal protection zone located directly adjacent to a module or module component, or directly between multiple modules or components of the line. For example, a hazardous situation can arise if modules or components that are movable relative to one another fail to maintain the minimum distances required due to operational or legal regulations. A hazardous situation can also arise if people or objects enter such a protection zone located directly adjacent to the production line.

[0017] Alternatively, the protection area can be an external protection area surrounding the production line, for example, a walkway or a driveway adjacent to the line. As explained in more detail elsewhere, the protection area can be divided into several protection zones. It is also possible for a respective protection area to be assigned to several modules. Furthermore, it can be provided that a respective protection area is monitored by either one or several sensors.

[0018] As is already clear from the above explanations, the movement that is adjusted depending on the result of the evaluation can be a movement of, for example, a module or a component of a module that occurs at a specific speed or with a specific acceleration. The movement can, for example, occur along intended travel paths. However, the movement can also be one that cannot be precisely predicted. The working movements of a pick-and-place robot (picker), for example, can depend, among other things, on the specific position of the portions to be picked up and are considered to be intended even if they cannot be precisely predicted in every respect.

[0019] The adjustment of the movement can, in particular, involve a reduction in the speed of the movement. However, the adjustment is not limited to this. Positive accelerations, for example, of modules or module components, can also be changed to achieve an adjustment of the movement.

[0020] If one or more modules or a larger unit of the entire production line, such as a packaging machine, operates in a cyclical manner, an adjustment of one or more movements can consist of decreasing or increasing the cycle frequency, i.e., changing the number of work cycles per unit of time. Furthermore, an adjustment of the movement can also be achieved, for example, by shortening the travel distances of one or more modules or one or more of their components, or by increasing the minimum distances to be maintained between components of the production line.

[0021] The assessment of a particular situation can, for example, always be carried out in the same way or it can be variable. In the latter case, the same situation, e.g. the intervention of an object in a protected area, can be assessed differently depending on whether the object is a permitted or a prohibited object. A permitted object can, for example, be the arm of an operator who is recognized as such by suitable means, whereby an arm of a person who is not recognized as an operator intervening in the same way is assessed as a prohibited object, the intervention of which consequently results in an adjustment of the movement, e.g. a slowing down of a moving module to reduce the risk of entrapment.

[0022] For example, if an operator is considered a permissible object, it can be assumed that the operator is aware of the potential hazard, so that no adjustment to the movement is made. In this example, a distinction can also be made according to the type of intervention, for example, if the protected area is divided into multiple protection zones. For example, if an intervention occurs in an inner protection zone closest to a potentially dangerous point on the line, the movement can be adjusted regardless of whether an object is prohibited or not, so that operators, for example, are also reliably protected.

[0023] An assessment concept can, for example, also consist of different guidelines or criteria applying to different modules or module components. A situation that is identified and assessed as a special situation in one module does not necessarily represent such a special situation in another module. Alternatively or additionally, the same special situation can be assessed differently for different modules.

[0024] Such evaluation concepts allow different hazardous situations to be defined for different modules within the protected area. This may be required or specified for design or operational reasons. For example, one module may allow faster deceleration to a non-critical value that is no longer considered dangerous than another module that, for example, cannot be decelerated as quickly for design reasons.

[0025] The assessment of a specific situation can change over time. In particular, the control system itself can learn or be taught. For example, if an operator on the production line is initially identified and assessed as an inadmissible object, but this operator is wearing specific work clothing – initially unknown to the control system – that is clearly identifiable by the sensor, then, upon subsequent detection of this specific work clothing, an assessment can be made that this object, i.e., the operator or, for example, an arm or hand of the operator, is not considered an inadmissible object.

[0026] For example, specific work clothing can be identified by its color or a specific color combination. White outerwear combined with colored work gloves, for example, can be reliably distinguished from the clothing of visitors or other persons not authorized to work on the production line. For example, the control system can use AI-based software (AI = Artificial Intelligence) to detect and evaluate special situations in this way.

[0027] The modules in the production line can, for example, be the following equipment:

[0028] Processing device, e.g. bacon press or cheese divider (product preparation)

[0029] Scanning device, e.g. scanner for determining the outer contour and / or scanner, e.g. X-ray scanner, for determining the internal structure of the food products

[0030] Loading device for product bars, e.g. loading swing, infeed device or loading magazine

[0031] Slicing device, in particular with driven cutting blade, lockable cutting head with cutting blade and drive for the cutting blade, adjustable cutting edge for cutting gap adjustment, interleaver, height and / or side adjustable portioning unit

[0032] Product grippers, especially with adjustable holding force, for example vacuum grippers

[0033] Scale

[0034] Underleaver

[0035] Transport line with conveyor, sorting, buffering and insertion devices, the latter for example in the form of insertion robots (especially pickers, i.e. pick-and-place robots)

[0036] Packaging station with

[0037] Forming station, e.g. deep drawing station such as thermoformer Insertion area (works together with insertion devices of the transport line to insert portions into recesses / trays) Sealing station

[0038] Labeling station / labeling device for applying labels to the packages

[0039] Printing station for printing the packages and / or labels Separating devices, in particular longitudinal and transverse separating devices for separating the packages

[0040] The sensor(s) can, in principle, be mounted anywhere along the production line, for example, on a labeler. Other possible modules with moving parts include, purely as examples: printing axes, film rolls, transversely movable conveyors, picking robots, relatively small robots for inserting additives such as mustard bags in a so-called ReadyMeal area, rockers, and stackers.

[0041] As already stated elsewhere, the invention makes it possible to adapt one or more movements of modules or module components occurring on the production line and thus, in particular, to control the performance of the modules in question or of the production line as a whole resulting from these movements depending on the sensor data. This advantageously creates a balance between the technically possible movements or speeds on the one hand, while taking safety aspects into account on the other. The safety aspects can relate both to the module or the production line itself and to external influences, in particular the intrusion of external objects into a respective protected area.

[0042] In this context, it should be emphasized that the invention not only makes it possible to slow down the operation of a module or the entire production line if a detected special situation is, for example, assessed as a hazardous situation. Rather, it is also possible to operate one or more modules or the entire production line at a higher performance, meaning faster, i.e., with faster movements, than is currently possible for safety reasons. Legal regulations, for example, may require that certain speeds or accelerations of moving parts of a production line must not be exceeded, even though this would be technically possible without detriment to the line or the module in question.The monitoring provided according to the invention and the possibility of influencing the movements taking place on the line make it possible, for example, to carry out rapid operation if there are no persons or non-intended or inadmissible objects in the respective protection area or in all defined protection areas of the line.

[0043] This allows for a significant increase in performance compared to current capabilities without the need to reinforce the production line itself. If the current situation in each protected area is considered safe or particularly safe, the production line can be operated purely according to efficiency or performance criteria, for example, with each module in mind. This means the production line can be "maximized," which was previously impossible for safety reasons.

[0044] By adapting the movement, the goal of maintaining specified safety distances can be achieved.

[0045] On the one hand, these can involve distances between the respective moving part of the production line and neighboring components. This makes it possible, for example, for the moving part to approach another component at maximum speed until a minimum distance, known as a gap, is reached. A minimum distance can, for example, result from a relevant entrapment hazard for people or certain parts of their bodies. Independently of this—and thus, to a certain extent, from the perspective of production line operation—permissible gaps can be determined with regard to the risk of component collision, taking into account braking processes and braking distances.A practical example of this is a labeler on a packaging machine, which comprises a so-called top web applicator as one module and a so-called bottom web applicator as another module. The former applies labels to the top web of the packages, while the latter applies labels to the bottom web. In practice, these two modules are moved independently relative to each other on one or more travel axes in a labeling area of ​​the packaging machine belonging to the production line.Since the invention can ensure compliance with minimum distances between the two modules or between one of the two modules and another module or a component thereof, such as the housing of a sealing station located upstream of the labeler, by monitoring appropriately arranged protection areas, the travel speed of the labeler modules can be increased since there is no need to provide for slower operation as standard as a precautionary measure to take into account the potential intrusion of objects.

[0046] Using such a labeler as an example, a further advantage of the invention can be highlighted. This advantage is that, in addition to controlling the position of the respective moving part—here, the upper and lower webers of the labeler along the aforementioned one or more travel axes—other special situations can be detected. A special situation can, for example, result from a changed outer contour of the upper or lower weber. For example, a sensor can detect an improper relative position of a component, such as a label supply roll that has been folded outward.If, in such a position, which is actually a maintenance position, operation of the module in question—here, the labeler—is nevertheless possible, then the production line does not need to be temporarily shut down to fold back the label supply roll. Instead, the production line can be temporarily operated at a reduced speed, e.g., until a new label supply roll is inserted, since the area of ​​the folded-down label supply roll, which could pose a potential hazard, can be monitored. Such a temporary slowdown of the production line can be advantageous for a variety of reasons compared to a production line standstill—even if only briefly.

[0047] Secondly, the invention can also ensure the maintenance of safety distances between a particular moving part and external objects (people or objects). The operation of the production line can thus be made dependent on whether such external influences are present or not in a defined environment of the production line.

[0048] As an example, it has already been explained above that a "quick operation" can be carried out, e.g. when the environment of the production line is detected as free.

[0049] If a person or an obstacle, such as an automatic conveyor vehicle in a travel path next to the line, is detected in the vicinity of the production line, the production line does not need to be stopped, but can be slowed down accordingly depending on the specific situation. This not only protects the detected person or object, but also results in more gentle operation than if the line were to come to an abrupt standstill. Abrupt braking processes can lead to wear or vibrations in the production line or individual modules, which, over a long period of operation, can shorten the service life of the affected components. In other words, the invention enables the production line to run through, thus reducing overall stress on the modules and components, particularly the moving parts.

[0050] The control device can be configured to use the provided sensor data to distinguish between people and objects, for example, by recognizing people and their body parts based on their respective outlines and thus distinguishing them from objects. This makes it possible to perform differentiated assessments and / or take differentiated measures to adapt the movement.

[0051] It has already been mentioned elsewhere that the control device itself can learn or be taught in. As explained, this can include recognizing specific work clothing. However, it is also possible for certain special situations to be assessed as not requiring any movement adjustment only after they have been taught in. For example, a label supply roll that is folded outwards, as already mentioned above, and is therefore in a maintenance position and protrudes laterally beyond the line, can be assessed by a taught-in control device as a permissible operating condition that does not lead to any movement adjustment. However, when this special situation is recognized for the first time, an assessment is made that a potentially dangerous situation is to be assumed and that a movement adjustment must therefore be carried out.

[0052] With regard to such learning processes of the control device, especially those supported by AI, the invention can exploit the fact that in production plants, the same conditions generally prevail during every work shift. This applies, for example, to the aforementioned specific work clothing, which can be learned by the control device as a recurring and thus admissible phenomenon. This also applies to other situations, such as recurring characteristics of certain objects.For example, the shape, size or colour of stationary objects such as boxes or of movable objects such as conveyor vehicles can be detected by the control device and, with the knowledge that these objects are actually allowed to be located where they are detected by the control device during normal operation, can be considered permissible, so that no adjustment of the movement takes place.

[0053] An evaluation by the control system does not have to be based exclusively on characteristics such as shape, size, or color. These characteristics can, for example, supplement the final evaluation, which may actually be based on a larger information base. This can ensure an optimization of the evaluation process.

[0054] Some concrete examples are given below.

[0055] For example, if a person is detected in the protected area, the affected module or the entire production line can slow down its performance so that one or more movements of moving parts of the line are slowed down. Additionally, a warning signal can be issued, for example. If the person leaves the protected area again, the production line can be configured to automatically increase the speed of the movement or movements again—and not only after an explicit acknowledgement by an operator.

[0056] Although the invention is particularly advantageous because it can prevent an automatic shutdown of a module or the entire production line when this is not absolutely necessary, as a last resort, an evaluation of a specific situation can also lead to the movement being adjusted within the scope of the invention, for example, by reducing the speed to zero, thus stopping the module or the entire production line. In this case, too, the line can be restarted automatically once the specific situation has ceased or the corresponding evaluation has been completed.

[0057] According to another application example, the protected area can be divided into several protection zones. While an intrusion into an outer protection zone only slows down the movement and, if necessary, issues a warning signal, a violation of a further inner protection zone can result in a greater reduction in speed or even a standstill of the affected module or production line.

[0058] It can also be provided that, when a zone is divided into several protection zones, an intervention in an outer, particularly the outermost, protection zone does not trigger a movement adjustment, but rather another measure is triggered, in particular, a visual and / or acoustic warning. Such a warning can, for example, only be triggered if persons identified as such intervene in the outer protection zone, in order to use this warning to prevent, as far as possible, an accidental (further) movement of the person in question into a further inner protection zone, which would then necessarily result in a movement adjustment.

[0059] If, on the other hand, an object is detected in the outer protection zone, it can be provided that no warning is given (since it is assumed that objects, unlike people, cannot be warned or cannot be warned easily), but that an immediate movement adjustment takes place.

[0060] If different protection zones are planned, these can be checked and corrected if necessary by performing a reference run of the module or the entire production line. Any resulting changes can be taught into the control system. Teaching can also be performed after modifications have been made to the production line.

[0061] It is also possible to store or program specific protected areas or subdivisions of a protected area into specific protected zones, for example, in a memory device of the control unit, in order to proceed recipe-by-recipe. In the field of food processing in question here, different applications, which differ from one another in particular with regard to the type of food products to be processed and / or the method of processing, are referred to as "recipes." A particular recipe is therefore also characterized by corresponding settings on the modules and modular components of the production line. Different recipes may, for example, require different protected areas, different protected zones into which a respective protected area may be divided, or different assessments of certain special situations.

[0062] For example, a change to a different food product may require a different package geometry, which no longer requires the entire, generally available travel range of a labeler. A smaller protection zone is then sufficient. In this case, a correspondingly reduced travel range of the labeler may also eliminate the risk of impact with other modules or components, nor the risk of operators becoming trapped, since critical gaps can no longer occur in such an application due to the shorter travel range.

[0063] Depending on the function of a particular module, it may be possible to slow down or stop only the affected module if necessary, allowing the production line to continue operating otherwise. This is possible, for example, if the affected module is a rocker or a stacker. Downstream of such a module, the packaging of portions on the packaging machine can continue without any disadvantages, at least for a certain period of time.

[0064] According to further examples, movement adjustment can be distance-dependent, speed-dependent, or direction-dependent. These criteria can, in principle, also be combined in any way.

[0065] In a distance-dependent response to a specific situation, the extent of a change in movement, particularly a deceleration of movement, can depend on the distance of a respective object (person or object) from a module or module component. If the object is a person, the potential risk of entrapment is a particularly relevant criterion in the control device's assessment of the specific situation.

[0066] With a speed-dependent response, for example, the control system can distinguish a person's stumble from normal, slow walking. For example, a stumble can be detected as a rapid movement toward the machine and assessed accordingly, so that such a special situation can even lead to an immediate stop of the production line rather than just a slowing down of the respective movement. In the case of a slow walking movement, however, a normal state can be assumed, so that if the person walking is sufficiently close to the production line, a slowing down of the movement may be sufficient for safety reasons, and a standstill is not necessary.

[0067] With a direction-dependent assessment, the control system can, for example, distinguish whether a person is walking along the production line parallel to the transport direction. This would only result in a slowdown of the respective movement of the module, the module component, or the entire production line if the person is relatively close to the production line. However, if it is detected that a person is moving toward the production line, i.e., the detected movement is not parallel to the transport direction, a greater reduction in speed or even a standstill of the production line can occur.

[0068] The aforementioned possible dependencies of a reaction with regard to distance, speed, and direction can also apply analogously to objects within a defined protection zone. In this case, it can be stipulated that lower safety requirements apply to objects insofar as an object that initially enters the protection zone but then stops moving and comes to a standstill results in the deceleration of the movement being reversed, as long as the object is not so close to the module or component in question that it is endangered by the moving part. In other words, smaller safety distances can apply to objects than to people.

[0069] After reducing the speed of movement of a moving part of the production line, the resumption of the original movement can be controlled, for example, by distance or time. For example, normal operation can resume as soon as the object in question has moved sufficiently far away from the module in question. If a sufficiently large distance from the object is not reached, normal operation can nevertheless resume if a predetermined period of time has elapsed without the object approaching the module in question, since in this case, it is assumed that reapproaching is sufficiently unlikely.This creates a sufficiently large safety buffer that minimizes the risk that, after resuming normal operations, a movement adjustment will have to be made again after a short period of time because the object in question causes a special situation that is considered critical.

[0070] The sensor can be attached to a movable module or integrated into it, allowing it to move along with the module. The advantage here is that the module is always provided with the same protection area and, if necessary, the same division into protection zones, regardless of its position.

[0071] Alternatively, the sensor can be permanently installed, for example, to monitor a protection zone that is best suited to the production line and is assigned to a working area of ​​a particular module or module component. The sensor can, for example, be positioned above a working or movement area of ​​the module or component. Lateral offset is also possible, allowing perspective monitoring of the working or movement area.

[0072] Furthermore, the sensor can be aligned, particularly with regard to predetermined walking routes, access areas or danger areas, in such a way that the movable module or the movable module component in question is always in the background of the monitored protection area and any objects entering the protection area are always in the foreground.

[0073] For example, a sensor can be checked from time to time using reference images. A reference image can correspond to a predefined operating state of the monitored module or component. If the control system correctly detects and evaluates such predefined situations, it is not necessary to use additional test objects or human "test interventions" to test a sensor. In addition to one or more sensors in the production line area, additional sensors can be provided elsewhere. For example, a camera can be mounted on the ceiling of a hall. Using such a sensor, additional information can be obtained and used, for example, to adjust the protection zones of sensors arranged along the production line.Depending on the overall situation detected by the additional sensor, certain default values ​​relating to a sensor located on the production line can, for example, be changed or even activated for the first time.

[0074] The invention enables efficient operation of the production line and thus higher performance while simultaneously ensuring a high level of safety for people and objects. Furthermore, greater flexibility can be achieved in the modules and their components, as the intended movements of the modules or components can be adapted to the respective situation.

[0075] Since the invention avoids the need to enclose modules or components, it allows easier access to individual modules, which in particular simplifies maintenance and conversion.

[0076] The invention also provides more freedom in the area surrounding the production line. Walkways and driveways in the vicinity of the production line can be better utilized, as there is no longer a risk of the production line being automatically stopped every time an object moves there.

[0077] As already mentioned elsewhere, the invention ensures that frequent, in most cases actually unnecessary, production line stops and the resulting restarts are avoided. This means that the production line can operate virtually continuously, keeping the entire production process reliably "flowing."

[0078] The operating and monitoring effort, as well as the measures required by operating personnel after production line stops, which can also cause operator uncertainty, are eliminated. Overall, this significantly reduces the workload for operating personnel.

[0079] The monitoring system provided by the invention allows any errors that may occur to be located immediately. Time-consuming troubleshooting by operating personnel is no longer necessary. It should be noted that, in practice, production lines can be quite long, which would make troubleshooting extremely time-consuming.

[0080] As already mentioned elsewhere, a further advantage of the invention is that the monitoring and thus the evaluation can be carried out depending on the recipe, so that an optimal monitoring concept can be provided for each specific application.

[0081] Possible further developments of the invention are also specified in the dependent claims, the following description, and the drawings. Examples of some of the further developments of the invention explained below are also given above.

[0082] It can be provided that the protection area is fixed or variable relative to the production line, in particular to a module or to a component of a module.

[0083] The protective area can, for example, be designed to "ride along" in that the protective area is fixed relative to a first module or a first component and thus movable relative to a second module and a second component, relative to which the first module or the first component moves during operation.

[0084] In some embodiments, a special situation can be detected by the fact that the sensor data deviate from predetermined, in particular previously learned, sensor data.

[0085] This makes it possible to compare a current situation, in particular on an ongoing basis, with one or more situations known to the control device.

[0086] It may be provided that the evaluation of a particular situation is carried out by comparison with at least one predetermined situation, in particular one that has been previously learned.

[0087] It may be provided that the given situation is changed on the basis of at least one previous assessment of the same particular situation or that the assessment of the particular situation is carried out differently on the basis of at least one previous assessment of the same particular situation.

[0088] This makes it possible for the control device to learn itself or for the control device to be taught in.

[0089] The particular situation may be a hazardous situation in which a person or an object belonging to the production line, or an external object not belonging to the production line, is exposed to at least a potential hazard from a module or component of a module of the production line. For example, the upper tool of the sealing station may be potentially endangered by a downstream upper web operator of the labeler. According to an alternative example, a module or component may have different positions and pose a potential hazard only in one position.For example, a label supply roll that is folded down to the side for roll changing and allows the production line to operate in the folded down state without error messages can nevertheless be potentially dangerous in this folded down state because it protrudes laterally from the production line and, for example, projects into an aisle next to the line.

[0090] The at least potential danger can arise from at least one moving part of a module or a component of a module.

[0091] In some embodiments, it may be provided that a special situation is recognized if a predetermined minimum distance between parts of the production line that are movable relative to one another is not maintained in the protected area.

[0092] As already mentioned elsewhere, for example, on a labeller the upper laner and the lower laner can be movable relative to each other and / or relative to other modules or module components, whereby minimum distances in the sense of gap dimensions must be maintained in order to avoid a risk of trapping for operating personnel.

[0093] According to some training courses, the intrusion of an object into the protected area can be recognized as a special situation.

[0094] Furthermore, it can be provided that an assessment of a particular situation is carried out depending on one or more additional predetermined conditions and / or depending on whether or not at least one predetermined situation has been detected in the same or another protection area.

[0095] For example, if there are no people in the area of ​​the production line or a specific module, the specified minimum distance to be maintained can be set smaller than when people are present. Movement adjustments can therefore be made dependent not only on the specific situation itself, but also on the additional conditions under which the specific situation occurs.

[0096] In some embodiments, at least one additional predetermined criterion can be taken into account for an evaluation of a particular situation, in particular wherein the additional predetermined criterion can be detected by the sensor monitoring the relevant protection area.

[0097] For example, the presence of a person in the protected area or the intervention of a person's body part in the protected area can be recognized as a special situation. If, for example, a camera forming the sensor can also detect the color of a certain part of the clothing or the presence of an authorization (e.g., a visual ID card), then the person can either be classified as authorized, for example, in the sense of having been instructed in the operation of the production line, which results in no or at most a slight slowing down of movement. Or the person can be classified as unauthorized, which results in a significant slowing down of movement or an immediate stop of the production line or the affected component.

[0098] For at least one module or at least one component of a module, several operating modes can be specified and the movement adaptation can be carried out by the control device causing a change from a current operating mode to another operating mode of the module or the component.

[0099] In some embodiments, it may be provided that the control device reverses the movement adaptation as soon as the special situation is no longer recognized.

[0100] For example, if an object interferes with the protection zone, the speed of the module in question, or of the entire production line, can be reduced and then increased again as soon as the protection zone is no longer violated. This reversal can be made dependent on confirmation from an operator, who must acknowledge the "free state," so to speak. However, this is not mandatory; reversing the movement adjustment can also occur automatically. It can also be specified that confirmation is only required for certain special situations.

[0101] The reversal of the movement adjustment can be delayed. The delay can be determined by the expiration of a specified period of time or by the reaching of a minimum distance from the protected area of ​​an object that previously triggered the movement adjustment.

[0102] According to some developments, the movement adjustment can be carried out by slowing down the movement, in particular wherein the slowed down movement is always kept above zero, unless a predetermined emergency situation is detected in which the control device stops the production line or at least one module of the production line.

[0103] As mentioned elsewhere, the concept of keeping the production line "always moving" is particularly advantageous in the food processing industry. Due to legal regulations, it is often necessary to package the portions produced during slicing of food products within a certain time. A line shutdown would increase the production time in the line. If the time is too long, it would be necessary to remove all portions from the line and restart the line. The risk of such interruptions can be minimized by the invention.

[0104] According to some embodiments, it can be provided that the movement adaptation takes place by changing a movement sequence of a module or a component of a module that is part of the intended operation.

[0105] For the purposes of the present disclosure, a movement is not necessarily limited to a movement along, for example, a straight or curved path. Rather, a movement can also comprise a sequence of movements, for example, a back-and-forth movement or even more complex sequences of movements, which can also occur in three dimensions.

[0106] It can be provided that the movement adjustment is carried out by reducing or increasing a speed or an acceleration of a movement of a module or a component of a module.

[0107] Alternatively or additionally, it can be provided that the movement adjustment is carried out in such a way that at least a minimum distance to be maintained between parts moving relative to one another is increased.

[0108] In some training courses, the protection area can be divided into several protection zones, and depending on which protection zone or zones are affected by a recognized special situation, the special situation can be assessed differently and / or the movement adaptation can be carried out differently.

[0109] Such a protection zone concept creates the possibility of escalation in such a way that, for example, the movement is slowed down the more the object comes closer to the line or the faster an object moves towards the line.

[0110] In general, even without a protection zone concept, the movement adjustment can be made depending on the position of an object in the protection zone and / or the distance of an object in the protection zone from the production line, from a module or from a component of a module.

[0111] For example, the control system can operate according to the concept that the closer the object is to the production line, the slower the movement occurs.

[0112] It can be provided that the movement adjustment takes place depending on the speed of an object in the protection area.

[0113] As already mentioned elsewhere, for example, a person walking slowly can be assessed as uncritical, whereas a person running or even stumbling can be recognized as such and assessed as critical.

[0114] According to some developments, the movement adjustment can be made depending on the direction of movement of an object in the protected area relative to the production line. As already explained above, a person walking close to, but parallel to, the line can be assessed as non-critical, while a person moving toward the line can be assessed as critical.

[0115] In some embodiments, it may be provided that a plurality of sensors are provided for monitoring a common protection area, and a particular situation in the common protection area can be assessed based on the sensor data of the plurality of sensors, or it may be provided that the production line comprises a plurality of sensors for monitoring different protection areas and either a particular situation in one of the protection areas or a particular situation concerning a plurality of protection areas is assessed as an overall situation based on the sensor data of a plurality of sensors.

[0116] Alternatively, it is also possible for one sensor to monitor multiple protection zones. For example, if each module is assigned a protection zone, one sensor can monitor multiple modules.

[0117] The control device can be designed to evaluate sensor data provided by several sensors monitoring the same or different protection areas.

[0118] In some developments, it can be provided that additional data is provided for the control device and the control device includes the additional data in the evaluation of the special situation, in particular wherein the additional data relates to information about the production line, about at least one module of the production line, about at least one component of a module and / or about the environment of the production line. The additional data can, for example, be provided by an additionally provided sensor system that relates to the production line, to a module or to a component of a module. Alternatively or additionally, this sensor system can relate to equipment in the environment of the production line, for example to equipment in the room or hall in which the production line is located. In general, the additional data or the information relating to the additional data can be of a wide variety of types.For example, the information may relate to a locking system for a room or hall, room or hall monitoring, or a person presence detector.

[0119] The control of the production line can thus be made dependent on more information than can be provided by the sensor or sensors that monitor the protection areas assigned to the production line.

[0120] Further possible embodiments of the production line according to the invention are given below.

[0121] The sensor can be designed to capture images, in particular depth-resolved images, of the protected area and / or to detect intrusions into the protected area.

[0122] The sensor can be, for example, a camera, e.g., a thermal imaging camera, a laser scanner, a radar sensor, a light barrier, or a light grid. Multiple sensors and combinations of different sensors can also be provided.

[0123] The sensor can be attached to or integrated into a movable module or a movable component of a module. The sensor can be mounted and aligned in such a way that a movable part of a module or a component of a module, which poses at least one potential hazard, is located in the background of the protected area, and potentially endangered objects can move into the foreground of the protected area.

[0124] The control device can be designed to evaluate sensor data provided by several sensors that monitor either the same or different protection areas.

[0125] For example, it can be configured for the sensors to monitor the same protection zone from different perspectives. Different protection zones can be separate or overlap.

[0126] The control device may comprise an evaluation device which is designed to evaluate the sensor data and assess the particular situation.

[0127] The invention is described below by way of example with reference to the drawings. They show:

[0128] Fig. 1 a and 1 b together schematically show in a side view a possible embodiment of a production line according to the invention, which can be operated in the manner according to the invention,

[0129] Fig. 2 is a diagram to explain the method according to the invention, and Figs. 3, 4 and 5 show possible embodiments of the invention using a section of a packaging machine which forms part of a production line according to the invention.

[0130] Fig. 1 a shows a schematic side view of a possible embodiment of a high-performance slicer 3 which, like the packaging machine 12 described below in connection with Fig. 1 b, forms a component of a possible embodiment of a production line 1 according to the invention.

[0131] Upstream of the slicer 3 is a scanning device 2, which may comprise a scanner, for example, operating according to the light section method, which serves to determine the outer contour of products 4 to be sliced. Alternatively or additionally, the scanning device 2 may comprise an X-ray scanner, which makes it possible to determine the internal structure of products 4 to be sliced.

[0132] In the example schematically illustrated here, the products 4 are guided through a housing of the scanner 2 by means of a conveyor belt 36 before being cut open and are scanned by two scanning units 2a. The determination of the outer contour of the products 4 in this manner is generally known to those skilled in the art, so it need not be discussed in more detail.

[0133] In the slicer 3, a product 4 to be sliced ​​rests on a product support 9a, which is inclined relative to the horizontal and comprises a driven or free-running endless belt or a fixed sliding surface for the product 4. The product support 9a can be designed in a basically known manner as a so-called loading swing arm, which can be pivoted between the inclined position shown and a horizontal loading position, so that products 4, fed by the conveyor belt 36 and coming from the scanner 2, reach the product support 4a and can then be brought into the inclined position according to Fig. 1a by pivoting.

[0134] In this inclined position according to Fig. 1a, a product holder 5a, which is designed, for example, as a gripper, can be brought into engagement with the rear end of the product 4. The product holder 5a can be moved in a feed direction Z by means of a spindle drive comprising a spindle nut 5b coupled to the holder 5a and a spindle 5c extending in the feed direction Z.

[0135] The product feed thus formed feeds a respective product 4 resting on the product support 9a to a cutting plane 6 running perpendicular to the feed direction Z, in which a cutting blade 7 moves. The cutting blade 7 can be a sickle blade that rotates exclusively about an axis of rotation running parallel to the feed direction Z. Alternatively, the cutting blade 7 can be a circular blade that rotates about an axis of rotation and additionally orbits planetarily about another axis, whereby these axes also run parallel to the feed direction Z.

[0136] The cutting knife 7 consequently carries out cutting movements, as a result of which slices 4a are separated from the correspondingly fed product 4, at cutting speeds of, for example, several hundred to several thousand slices per minute.

[0137] The contour and / or structure determination using the scanner 2 serves to obtain information about the density distribution of the products 4. In addition, the products 4 are weighed using a scale (not shown). Alternatively, assumptions about the average product density can be used, e.g., in the form of stored values. Consequently, by controlling the product feed, the thickness of a respective slice 4a and thus the weight of a slice 4a or a portion 10 formed by several slices 4a can be specified.

[0138] Such a weight-accurate slicing of food products 4 by means of a high-performance slicer 3 in order to obtain weight-accurate slices 4a and / or portions 10, which are sold to end consumers by the food trade after packaging in a packaging machine (cf. Fig. 1 b), is basically known to the person skilled in the art.

[0139] The portions 10 are formed from the falling, separated slices 4a on a portioning belt 30. By means of the portioning belt 30, the formed portions 10 are transported away and transferred to a transport line not shown in detail in Fig. 1a.

[0140] The operation of scanner 2 and slicer 3 is controlled by a control device 3a assigned to slicer 3, which communicates with a control device 60 of the entire production line 1 (explained in more detail below) or forms a component of this control device 60 (see Fig. 1 b). However, such a separate control device 3a is not mandatory. Scanner 2 and slicer 3 can also each communicate directly with the central control device 60.

[0141] The portions 10 are transported via the aforementioned transport path to the packaging machine 12 shown in Fig. 1 b and explained in more detail below.

[0142] A so-called inserter, of which two endless conveyor belts 13a, 13b are shown here, can be used to insert the portions 10 into the packaging machine 12. Alternatively, the portions 10 can be inserted by one or more robots 50, each comprising a gripper 49 for picking up and placing the portions 10; i.e., the robot 50 can, in particular, be a so-called picker. The portions 10 are inserted into the packaging machine 12 at an insertion station 13 of the packaging machine 12.

[0143] The packaging machine 12, operating in a transport direction T, comprises a machine frame 47. A transport chain 27, shown only schematically here at the upstream end of the machine, is guided on a left side frame and a right side frame of the machine frame 47. The two transport chains 27 together form a transport device for a bottom film 23 pulled from a supply roll 23a.

[0144] The machine comprises a plurality of work stations following one another in the transport direction T, which in the present disclosure are synonymously referred to as modules, namely a forming station 11, which in some applications is also referred to as a deep-drawer or thermoformer, the already mentioned insertion station 13 for products 10 to be packaged, a feed station 14 for a top film 25 pulled off a supply roll 25a, a labeling and / or printing station 16, a transverse cutting station 17 and a longitudinal cutting station 19.

[0145] The products 10 to be packaged are food products, here in the form of so-called portions, each comprising several slices which—as explained above with reference to Fig. 1a—were separated from a loaf- or bar-shaped food item, such as sausage, cheese, ham, or meat, using a food slicer (not shown here). The scanner 2 and the slicer 3 according to Fig. 1a and the packaging machine 12 are components of a production line 1 according to the invention.

[0146] The operation of the packaging machine 12, including the aforementioned modules, is controlled by the central control device 60 of the production line 1. As mentioned, the scanner 2 and the slicer 3, as well as all other modules of the production line 1, are also controlled by this central control device 60.

[0147] The packaging machine 12 is provided with an operating device 45, which comprises, for example, a touchscreen, on which all necessary information can be displayed to an operator and the operator can make all necessary settings before and during operation of the machine.

[0148] The basic structure and principle of operation of the workstations mentioned are known to the person skilled in the art, so they will not be discussed in detail here.

[0149] At the forming station 11, which comprises an upper tool 11a and a lower tool 11b, depressions 29, also referred to as troughs, are formed in the lower film 23 in a deep-drawing process. The aforementioned portions 10 are inserted into these depressions 29 at the insertion station 13. The insertion station 13 here comprises the aforementioned inserter with the two endless conveyor belts 13a, 13b, wherein alternatively or additionally the insertion station 13 can comprise the aforementioned picking robot 50. This can be designed, for example, in the form of a delta robot with a gripper 49, which has two scoops each holding a portion 10 together. Such robots 50 and their use in handling foodstuffs, in particular in inserting portions 10 into depressions 29 of packs 21, are generally known to those skilled in the art, which is why further explanations are not necessary here.

[0150] Subsequently, the bottom film 23, provided with the filled recesses 29, and the top film 25 are fed to the sealing station 15, which comprises an upper tool 15a and a lower tool 15b. These tools 15a, 15b bond the top film 25 and the bottom film 23 together. This seals the recesses 29 and thus the packages 21 formed by the top film 25 and bottom film 23. Sealing points 43, also referred to as sealing seams, running transversely to the transport direction T, are schematically indicated in Fig. 1a.

[0151] Following the sealing station 15, the packs 21 are still connected by the top film 25 and the bottom film 23, and therefore still need to be separated. In the embodiment shown here, the packs 21 are labeled and / or printed at the labeling device 16 before being separated. Labeling and printing can also be performed in separate stations.

[0152] Downstream of the separation stations 17, 19, further conveyor belts and / or work stations can be provided, for example a scale for checking the weight of the packages 21.

[0153] Applications can differ from one another, for example, with regard to the type of products 10 to be packaged, the size / shape of the recesses 29 in the longitudinal and / or transverse direction, or with regard to a format set. A format set generally refers to a group of items, in particular both portions 10 and recesses 29 or packages 21, which are handled as a whole—i.e., per format set—and which differ from one another, in particular, in the number and spacing of items in the longitudinal and transverse directions.

[0154] For example, per work cycle of the packaging machine 12, a pack format or format set of 3 x 4 (3 in the transverse direction and 4 in the longitudinal direction) recesses 29 or other product receptacles can be formed in the forming station 11, a format set of 3 x 4 correspondingly arranged products 10 can be inserted into a respective format set of recesses 21 at the insertion station 13, and a respective format set of 3 x 4 recesses 29 filled with products 10 can be sealed at the sealing station 15. The same applies to the labeling device 16.

[0155] In principle, an arbitrarily dimensioned N x M format set can be created, with N > 2 and M >= 1 .

[0156] On the production line 1 shown in Figs. 1a and 1b, specifically on the scanner 2, the slicer 3, and the packaging machine 12, several sensors 54 are arranged, each embodied as a camera. Each camera 54 monitors a protected area (not shown in detail here), which encompasses a specific spatial area of ​​the production line 1 and is assigned, in particular, to one of the modules.

[0157] In the embodiment shown here, a protection zone is assigned to the area between sealing station 15 and labeling station 16. Furthermore, a camera 54 monitors a protection zone assigned to the transverse cutting station 17 and the longitudinal cutting station 19, respectively.

[0158] Another camera 54 monitors the area between the insertion station 13 and the sealing station 15. Another protective area is assigned to the insertion station 13. Furthermore, Fig. 1 b shows a camera 54 at the upstream end of the packaging machine 12, which monitors a protective area assigned to the area where the bottom film 23 coming from the supply roll 23a engages with the aforementioned transport chains 27.

[0159] In Fig. 1a, purely by way of example, a camera 54 is shown in the scanner 2, which monitors a protection area assigned to the scanner 2. Furthermore, a protection area is assigned to the portion formation area of ​​the slicer 3, which is monitored by a further camera 54. The cameras 54 communicate directly or via a separate control device, such as the control device 3a shown in Fig. 1a and assigned to the scanner 2 and the slicer 3, with the central control device 60 via respective data transmission means 38. As a result, sensor data 83 relating to the monitoring can be provided to the control device 60 from the cameras 54, which are sensors within the meaning of the present disclosure.

[0160] The control device 60 has an evaluation device 61 which serves to evaluate the sensor data 83 and to assess a respective particular situation.

[0161] The control device 60 of production line 1 receives not only the sensor data 83 from the aforementioned cameras 54, but also additional data 83a via a sensor system 91 provided in addition to the cameras 54. Purely by way of example, this sensor system 91 can comprise a camera 91 mounted on a hall ceiling 89, a hall monitoring device, a hall locking system, or a hall presence detector. At least some of these devices 91 can be mounted, for example, on a hall wall 90.

[0162] The additional data 83a provided by this additional sensor system 91 relates to information about the environment of the production line 1. Further additional data 83a can be provided to the control device 60 by additional sensors 56, which—unlike the aforementioned cameras 54—do not monitor a protected area. These additional sensors 56 can, for example, be arranged downstream of the packaging machine 12 and assigned, for example, to a device for the final inspection of the finished packages 21 or to a device for packaging the packages 21 ready for dispatch.

[0163] At the upstream conveyor 13b of the aforementioned insert, Fig. 1b shows, purely by way of example, that such an additional sensor 56 can also be assigned to a respective conveyor device of the transport line. In Fig. 1a, purely by way of example, an additional sensor 56 is assigned to the slicer 3, specifically in the region of the upstream end of the product feed spindle 5c.

[0164] By means of such additional sensors 56, the control device 60 can, for example, be provided with measured values ​​of basically any parameters relevant to the operation of a respective production line 1.

[0165] Fig. 2 shows the production line 1 explained above in schematic form, in particular with regard to the infrastructure comprising the mentioned cameras 54 and additional sensors 56 as well as the central control device 60.

[0166] The production line 1 is shown schematically in Fig. 2 by its individual modules 1a. The production line 1 comprises the scanner 2 and the slicer 3 (see Fig. 1a), as well as the packaging machine 12 (see Fig. 1b). Between the slicer 3 and the packaging machine 12 is the aforementioned transport section 76, of which the endless conveyor belts 13a, 13b of the inserter are shown in Fig. 1b.

[0167] Modules 74 for product preparation are installed upstream of scanner 2. These modules can include, for example, a cheese cutter or a bacon press.

[0168] Furthermore, the production line 1 of the packaging machine 12 comprises downstream modules, which may include a final inspection module 78, for example a so-called end-of-line scale, as well as a module 80 for packaging the finished packages 21.

[0169] Each of these modules 1a can be assigned at least one sensor in the form of one of the aforementioned cameras 54. However, this is not mandatory. Purely by way of example, only one additional sensor 56, but no camera 54, is provided for one of the product preparation modules 74 and for the final inspection module 78. Thus, Fig. 2 illustrates that not every module 1a of a production line 1 needs to be assigned a protected area monitored by a sensor, e.g., in the form of a camera 54.

[0170] Furthermore, one or more additional sensors 56 can be assigned to the individual modules 1a. Purely by way of example, one of the product preparation modules 74 is shown as not having an additional sensor assigned to it, but rather only a sensor in the form of a camera 54 for monitoring a protected area assigned to this product preparation module 74.

[0171] The individual sensors 54, 56 can communicate directly with the control device 60 to provide the respective sensor data or additional data for the control device 60. As shown, however, so-called station-internal control devices 72 can be provided for at least some of the modules 1a, which can assume certain control tasks for the respective module 1a.

[0172] 3, 4 and 5 each show a section of the packaging machine 12 shown in Fig. 1 b. Shown (in Fig. 3 in plan view, in Figs. 4 and 5 each in side view) is an area between the upper web applicator 16a, which forms a component of the labeling station 16, on the one hand, and the upper tool 15a of the sealing station 15, on the other. The sealing station 15, including the upper tool 15a, is arranged stationary with respect to the transport direction T during operation of the packaging machine 12. The upper web applicator 16a, which is provided with a label supply roll 16b - just like the lower web applicator of the labeling station 16 (not shown here) - can be moved in both directions with respect to the transport direction T at a speed v, as indicated by the two arrows. The upper web applicator 16a serves to apply labels to the upper film 25.Accordingly, the lower web applicator (not shown) of the labeling station 16 serves to apply labels to the lower film. The explanations of exemplary embodiments of the invention given here in connection with a labeling station 16 or the upper web applicator 16a as an example apply analogously to other modules or components that can be moved relative to one another, not only of the packaging machine 12, but also, depending on the specific design, to other units of the entire production line 1. For example, the component 16a shown in Figs. 3, 4 and 5 can, in an alternative design, also be a printing device that can be moved in and against the transport direction T and serves to print the packages or the labels attached to the packages.

[0173] According to Fig. 3, the aforementioned area between the upper tool 16a and the upper tool 15a is assigned a spatial protection zone 81, which is ultimately defined in software and thus virtually by the control device 60 or its evaluation device 61 such that everything located outside the protection zone 81 is not taken into account, even if the camera 54 monitoring the protection zone 81 has a field of view that extends beyond the protection zone 81 at least in some spatial directions. The protection zone 81 is defined as a volume that includes everything relevant to a particular monitoring task. Alternatively, everything within the field of view of the cameras 54 can form the protection zone 81.

[0174] In the exemplary embodiment shown here, the protective area 81 is divided into three protective zones 81a. Since the upper tool 15a - as mentioned - is stationary and thus the upper web operator 16a moves along the packaging machine 12 relative to the upper tool 15a, the right-hand protective zone 81a in Fig. 3 can be referred to as the inner or innermost protective zone 81a. The left-hand protective zone 81a in Fig. 3 then represents an outer protective zone 81a. The distance between the upper web operator 16a and the upper tool 15a, measured along the transport direction T, is designated A in Fig. 3. In this example, a minimum distance Amin is specified in the sense of a gap dimension, which must not be undercut during operation of the packaging machine 12, for example due to legal regulations. In other words, the upper web operator 16a must not come closer to the upper tool 15a than the minimum distance Amin.

[0175] During the movement of the upper web operator 16a during operation of the packaging machine 12, the control device 60 is able to control the upper web operator 16a based on position control of the upper web operator 16a such that the specified minimum distance Amin is maintained during normal operation. During this normal operation, the camera 54 therefore does not serve to regulate the movement of the upper web operator 16a in such a way as to prevent the minimum distance Amin from being exceeded.

[0176] Rather, the camera 54 together with the control device 60 ensures that the upper track operator 16a can be moved back and forth at a maximum speed as intended during normal operation, as long as no intervention in one of the protection zones 81a of the protection area 81 is detected.

[0177] If, for example, a person 85 comes so close to the packaging machine 12 in this area during operation that an intrusion into the outer protection zone 81a occurs, this person 85 or a body part of this person 85 is recorded by the camera 54 as an object in the outer protection zone 81a. Based on the corresponding sensor data, the control device 60 recognizes a special situation therein.

[0178] If, based on certain criteria, such as those mentioned in the introductory part of the present disclosure, the control device 60 concludes during its assessment that this person 85 or their body part does not constitute a permissible object in the outer protection zone 81a, this is assessed as a dangerous situation. The control device 60 then generally maintains the operation of the packaging machine 12, including with regard to the movement of the upper conveyor operator 16a, but slows down the travel speed of the upper conveyor operator 16a. This is because it is possible that, during further operation, the upper conveyor operator 16a comes so close to the upper tool 15a that the minimum distance Amin is not reached. This would be uncritical for the operation of the packaging machine 12, but could pose a risk of entrapment for the person 85.

[0179] The travel speed v of the upper conveyor operator 16a can be further reduced if it is detected that the person 85 or their body part is now located in the central protection zone 81a. Furthermore, the upper conveyor operator 16a or the entire packaging machine 12 or the entire production line 1 can be stopped by the control device 60 as a "last resort" if the control device 60 detects an intrusion into the inner protection zone 81a based on the sensor data of the camera 54, which is considered an emergency situation.

[0180] Consequently, production line 1 is only shut down if an actual emergency situation (violation of the inner protection zone 81a) exists. If there is only a potential danger to a person 85 (violation of the outer or middle protection zone 81a), production line 1 can continue to operate. Slower operation is advantageous over a standstill, as already explained elsewhere.

[0181] Due to this monitoring system according to the invention, production line 1 can be operated at increased capacity during normal operation compared to prior art production lines 1, provided there is no violation of one of the protection zones 81a, since – as explained – the upper conveyor 16a can be moved at a high speed that fully exploits the technical possibilities. Furthermore, it can be provided that the aforementioned minimum distance Amin may be undercut during such normal operation.

[0182] In the embodiment of Figs. 4 and 5, the monitoring sensor is not a camera, but rather a distance sensor 54, which can measure the distance to objects that lie along the direction of travel of the upper conveyor 16a in a direction opposite to the transport direction T. In the embodiment shown here, such an object is the upper tool 15a. This embodiment illustrates that the sensor 54 used to monitor a protected area 81 does not have to be a camera for recording images of the protected area 81.

[0183] As long as the measured distance A is greater than the sum of the specified minimum distance Amin and a safety margin x, as shown by way of example in Fig. 4, the control device 60 operates the upper tracker 16a at a high travel speed v1. This ensures high-performance operation.

[0184] If the measured distance A equals or falls below the sum of Amin and X (Fig. 5), this is recognized by the control device 60 as a special situation in the protection zone 81 based on the sensor data provided by the distance sensor 54 and, for example, is always evaluated as a critical situation, regardless of other conditions, which leads to an adjustment of the travel speed of the upper track operator 16a in the sense of a deceleration. The upper track operator 16a will then travel at a reduced speed v2 < v1.

[0185] With this concept, the upper tracker 16a is moved comparatively slowly when it is close to the upper tool 15a—defined by the minimum distance Amin and the safety margin X. Such movement adjustment can be even more differentiated if the protection area 81 is divided into different protection zones 81a—as in the example in Fig. 3. The deceleration can then be more pronounced the closer the upper tracker 16a gets to the upper tool 15a.

[0186] A further situation-adaptive control can be achieved by making the amount of the safety allowance X dependent on the respective concrete situation. For example, the amount of X can be increased in the sense of increasing safety if a person 85 (cf. Fig. 3) or another external object, such as an external item in the form of a conveyor vehicle 87 moving in the area of ​​the production line 1 (cf. Fig. 4), is located in the vicinity of the production line 1. Even if such an object cannot intervene in the area between the upper conveyor operator 16a and the upper tool 15a like a person 85, a safety concept for the operation of the production line 1 can provide that an increased risk potential can nevertheless be assumed if external objects of any kind are located in the area of ​​the production line 1, or at least in the area of ​​the respectively monitored protection area 81.

[0187] The presence of such an object 85, 87 can be detected by an additional sensor. This additional sensor can be a camera mounted on the relevant section of the packaging machine 12, to which a corresponding additional protection zone is assigned. Alternatively, such external objects can be detected, for example, by a hall sensor 91, particularly in the form of a camera, mounted on the hall ceiling 89 (see Fig. 1 b).

[0188] The size of the safety margin X can also be made dependent on further conditions. For example, a sensor integrated into the upper weber 16a (not shown here) or another camera can detect whether a label supply roll 16b of the upper weber 16a is in a normal operating position or in a laterally folded-down maintenance position, which is indicated by dashed lines in Fig. 5.

[0189] In the maintenance position, the supply roll 16b can protrude comparatively far to the side, thus posing a potential hazard to the corresponding area on the packaging machine 12. If operation of the packaging machine 12 and thus of the production line 1 as a whole is still possible in this maintenance position, the control device 60 can consequently move the upper conveyor 16a along the packaging machine 12 in the intended manner even with the supply roll 16b folded down to the side. Due to the increased hazard potential when the supply roll 16b is folded down, the control unit 60 can increase the safety margin X, so that a slowing down of the movement of the upper conveyor 16a occurs even at larger measured distances A.

[0190] The examples explained above make it clear that the invention enables operation of the production line 1 at high performance if it is ensured that there is no or at least no relevant safety risk, while at the same time ensuring maximum safety, since the control device 60 can react flexibly to changes in the situation that can be detected and evaluated by means of the sensor-supported monitoring of protection areas 81 and, if necessary, by taking into account additional information provided by further sensors or other sources.

[0191] According to some possible embodiments of the invention, the packaging machine or a labeling station of the packaging machine can be designed as disclosed in German patent application DE 10 2023 1 10 423.3, which was filed with the German Patent and Trademark Office on April 24, 2023. The content of this patent application, at least as far as the packaging machine and the labeling device disclosed therein, each with regard to all described further developments, is hereby incorporated by reference. The packaging machine of the production line disclosed herein can therefore be designed and operated as disclosed in the cited patent application DE 10 2023 1 10 423.3. Furthermore, the labeling station of the packaging machine of the production line disclosed herein can be constructed and operated as described in the cited patent application DE 10 2023 1 10 423.3 is disclosed by means of the labelling device.

[0192] The packaging machine disclosed in the cited patent application DE 10 2023 1 10 423.3 can therefore be operated as a component of a production line disclosed therein according to one of the methods disclosed therein. Furthermore, the labeling device disclosed in the cited patent application DE 10 2023 1 10 423.3 can be operated as a component of a packaging machine disclosed therein according to one of the methods disclosed therein.

[0193] List of reference symbols

[0194] production line

[0195] 1 a Module

[0196] 1 b component

[0197] 2 scanning device, scanner

[0198] 2a Scanning unit

[0199] 3 Slicing device, slicer

[0200] 3a Control device

[0201] 4 Food product

[0202] 4a disc

[0203] 5 Product feed

[0204] 5a Product holder

[0205] 5b spindle nut

[0206] 5c spindle

[0207] 6 Cutting plane

[0208] 7 cutting blades

[0209] 9a Product edition

[0210] 10 servings

[0211] Forming station

[0212] 11 a Upper tool 11 b Lower tool 12 Packaging machine 13 Insertion station

[0213] 13a Endless conveyor belt 13b Endless conveyor belt 14 Feed station 15 Sealing station

[0214] 15a Upper tool 15b Lower tool 16 Labeling station

[0215] 16a Component (upper lane operator of the labeling station) 16b Label supply roll 17 Cross-cutting station

[0216] 19 Longitudinal separation station

[0217] 21 pack

[0218] 23 Bottom film 23a Supply roll 25 Top film

[0219] 25a Supply roll 27 Transport chain 29 Recess 30 Portioning belt

[0220] 36 Conveyor belt 38 Data transmission device 43 Sealing point 45 Operating device

[0221] 47 Machine frame 49 Gripper 50 Robot

[0222] 54 Sensor, Camera

[0223] 56 Sensor 58 Scale 60 Control device

[0224] 61 Evaluation device 72 Station-internal control device 74 Product preparation module

[0225] 76 Transport line 78 Final inspection module 80 Final packaging module

[0226] 81 Protection area 81 a Protection zone 83 Sensor data

[0227] 83a Additional data

[0228] 85 Person 87 External object, conveyor vehicle 89 Hall ceiling

[0229] 90 Hall wall 91 Sensors

[0230] Z Feed direction T Transport direction v Speed

[0231] A measured distance Amin minimum distance X safety margin

Claims

Claims 1 . Method for operating a production line (1 ) comprising several modules (1 a), in which Food products (4) are cut into slices (4a), portions (10) are formed from one or more slices (4a) each, and the portions (10) are packaged, and the at least one slicing device (3), in particular a high-performance slicer, for slicing the products (4) and for forming the portions (10), a packaging machine (12) for packaging the portions (10), a transport path (76) for handling the portions (10) between the slicing device (3) and the packaging machine (12), and a control device (60), wherein the production line (1) further comprises at least one sensor (54) for monitoring at least one protection area (81) assigned to the production line (1), wherein the sensor (54) provides sensor data (83) relating to the monitoring to the control device (60), and wherein the control device (60) detects a particular situation in the protection area (81) based on the provided sensor data (83),evaluates the detected special situation and, depending on the result of the evaluation, adapts a movement of at least one module (1 a) or at least one component (1 b) of a module (1 a) of the production line (1 ).

2. Method according to claim 1, wherein the protection area (81) is fixed or variable relative to the production line (1), in particular to a module (1 a) or to a component (1 b) of a module (1 a).

3. Method according to claim 1 or 2, wherein a particular situation is detected in that the sensor data (83) deviate from predetermined, in particular previously learned, sensor data (83).

4. Method according to one of the preceding claims, wherein the evaluation of a particular situation is carried out by comparison with at least one predetermined, in particular previously learned, situation.

5. The method according to claim 4, wherein the predetermined situation is changed due to at least one previous assessment of the same particular situation or wherein the assessment of the particular situation is different due to at least one previous assessment of the same particular situation.

6. Method according to one of the preceding claims, wherein a particular situation is a dangerous situation in which a person (85) or an object (15a) belonging to the production line (1) or an external object (87) not belonging to the production line (1) is exposed to at least a potential danger from a module (1a) or from a component (1b) of a module (1a) of the production line (1).

7. The method according to claim 6, wherein the at least potential danger originates from at least one moving part (16a) of a module (1a) or a component (1b) of a module (1a).

8. Method according to one of the preceding claims, wherein a special situation is recognized when, in the protection area (81), a predetermined minimum distance (Amin) between parts (15a, 16a) of the production line (1) that are movable relative to one another is not maintained.

9. Method according to one of the preceding claims, wherein the penetration of an object (85, 87) into the protection area (81) is recognized as a special situation.

10. Method according to one of the preceding claims, wherein an evaluation of a particular situation takes place as a function of one or more additional predetermined conditions and / or as a function of whether or not at least one predetermined situation has been detected in the same or a further protection area (81).

11. Method according to one of the preceding claims, wherein at least one additional predetermined criterion is taken into account for an evaluation of a particular situation, in particular wherein the additional predetermined criterion can be detected by the sensor (54) monitoring the relevant protection area (81).

12. Method according to one of the preceding claims, wherein several operating modes are predetermined for at least one module (1 a) or at least one component (1 b) of a module (1 a), and the movement adaptation is carried out in that the control device (60) causes a change from a current operating mode to another operating mode of the module (1 a) or the component (1 b).

13. Method according to one of the preceding claims, wherein the control device (60) reverses the movement adaptation as soon as the special situation is no longer recognized.

14. The method according to claim 13, wherein the reversal of the movement adjustment takes place with a delay, in particular wherein the delay is determined by the expiration of a predetermined period of time or by the reaching of a minimum distance (Amin) of an object (85, 87) previously triggering the movement adjustment from the protection area (81) or from a protection zone (81a) of a protection area (81).

15. Method according to one of the preceding claims, wherein the movement adaptation takes place by slowing down the movement, in particular wherein the slowed down movement is always kept above zero, unless a predetermined emergency situation is detected in which the control device (60) stops the production line (1) or at least one module (1a) of the production line (1).

16. Method according to one of the preceding claims, wherein the movement adaptation is carried out by changing a movement sequence of a module (1 a) or a component (1 b) of a module (1 a) belonging to the intended operation.

17. Method according to one of the preceding claims, wherein the movement adjustment is carried out by reducing or increasing a speed or an acceleration of a movement of a module (1 a) or a component (1 b) of a module (1 a).

18. Method according to one of the preceding claims, wherein the movement adjustment is carried out in such a way that at least one minimum distance (Amin) to be maintained between parts (15a, 16a) moving relative to one another is increased.

19. Method according to one of the preceding claims, wherein the protection area (81) is divided into a plurality of protection zones (81a) and depending on which protection zone (81a) or which protection zones (81a) are affected by a recognized special situation, the special situation is assessed differently and / or the movement adaptation is carried out differently.

20. Method according to one of the preceding claims, wherein the movement adaptation takes place as a function of the position of an object (85, 87) in the protection area (81) and / or of the distance of an object (85, 87) located in the protection area (81) from the production line (1), from a module (1a) or from a component (1b) of a module (1a).

21. Method according to one of the preceding claims, wherein the movement adaptation takes place as a function of the speed of an object (85, 87) in the protection zone (81).

22. Method according to one of the preceding claims, wherein the movement adjustment takes place as a function of the direction of movement of an object (85, 87) in the protection area (81) relative to the production line (1).

23. Method according to one of the preceding claims, wherein the production line (1) comprises a plurality of sensors (54) for monitoring a common protection area (81) and a particular situation in the common protection area (81) is assessed on the basis of the sensor data (83) of the plurality of sensors (54), or wherein the production line (1) comprises a plurality of sensors (54) for monitoring different protection areas (81) and either a particular situation in one of the protection areas (81) or a particular situation concerning a plurality of protection areas (81) is assessed as an overall situation on the basis of the sensor data (83) of a plurality of sensors (54).

24. Method according to one of the preceding claims, wherein the control device (60) is designed to evaluate sensor data (83) provided by a plurality of sensors (54) monitoring the same or different protection areas (81).

25. Method according to one of the preceding claims, wherein additional data (83a) are provided for the control device (60) and the control device (60) includes the additional data (83a) in the evaluation of the special situation, in particular wherein the additional data (83a) relate to information about the production line (1), about at least one module (1a) of the production line (1), about at least one component (1b) of a module (1a) and / or about the environment of the production line (1).

26. Production line (1 ) in which Food products (4) are cut into slices (4a), portions (10) are formed from one or more slices (4a) each, and the portions (10) are packaged, and the at least one slicing device (3), in particular a high-performance slicer, for slicing the products (4) and for forming the portions (10), a packaging machine (12) for packaging the portions (10), a transport path (76) for handling the portions (10) between the slicing device (3) and the packaging machine (12), and a control device (60), wherein the production line (1) further comprises at least one sensor (54) for monitoring at least one protection area (81) assigned to the production line (1), wherein the sensor (54) is designed to provide sensor data (83) relating to the monitoring to the control device (60), and wherein the control device (60) is designed toto detect a particular situation in the protection area (81) based on the provided sensor data (83), to evaluate the detected particular situation and, depending on the result of the evaluation, to adapt a movement of at least one module (1 a) or at least one component (1 b) of a module (1 a) of the production line (1).

27. Production line according to claim 26, wherein the sensor (54) is designed to capture images, in particular depth-resolved images, of the protection area (81) and / or to capture interventions in the protection area (81).

28. Production line according to claim 26 or 27, wherein the sensor (54) is attached to or integrated into a movable module (1a) or a movable component (1b) of a module (1a).

29. Production line according to one of claims 26 to 28, wherein the sensor (54) is mounted and aligned such that a movable part (16a) from which at least one potential hazard emanates, of a module (1a) or of a component (1b) of a module (1a) is located in the background of the protection area (81) and potentially endangered objects (85, 87) can reach the foreground of the protection area (81).

30. Production line according to one of claims 26 to 29, wherein the control device (60) is designed to evaluate sensor data (83) provided by a plurality of sensors (54) monitoring the same or different protection areas (81).

31. Production line according to one of claims 26 to 30, wherein the control device (60) comprises an evaluation device (61) which is designed to evaluate the sensor data (83) and to assess the particular situation.

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