Method and system for controlling container handling facility

Abstract

To improve a controlling system for a container handling facility, and in particular, simplify the parameterization thereof.SOLUTION: A container handling facility 1 includes: at least one container handling station 10, 20, 30, 40, 50, 60, 70, 80 for handling a container; and allocated controlling means 9, 19, 29, 39 for controlling the container handling process. The method of controlling the container handling facility 1 includes: sending real time process data from the controlling means to automatic process adjustment means 200; data being acquired by one or more sensors of the container handling facility; at least one process parameter being determined by the automatic process adjustment means depending on the received data; writing the determined parameters on the controlling means and adjusting the process of the container handling station.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to a method for controlling a beverage filling facility including a container handling facility, particularly at least one container handling station for handling containers and assigned control means for controlling the container handling process of the container handling station, and to a system including the container handling facility.

Background Art

[0002] In the beverage filling industry, including equipment and processes for filling, manufacturing, capping, labeling beverages and the like, increasingly complex control systems are used to automatically or semi-automatically bring about the setting of industrial equipment. For example, Patent Document 1 and Patent Document 2 describe methods for automatically adjusting the process parameters of filling equipment.

[0003] Changes in product type, such as commissioning of that type of equipment or changes in the product or container format to be filled, are brought about, for example, by an operator selecting a previously created product type within the menu of an HMI module ("Human Machine Interface Module"). Machine and process parameters (filling pressure, pressurization time, filling curve, etc.) are stored as a data record for the selected product type and used for controlling the equipment. Alternatively, the product type may be centrally managed within an LMS (Line Management System) and transferred to the corresponding equipment upon request.

[0004] The machine and process parameters for a desired product type, also referred to here as "product type parameters," can be determined by the use of algorithms ranging from simple formulas to complex, rule-based computational principles that can flexibly respond to different process and environmental conditions. These product type parameters are implemented within the control system for each product type when the machine is delivered and the filling process is subsequently determined. Possible inputs for the algorithms are product-specific parameters (e.g., Brix level, CO2 content, temperature, etc.), container-specific parameters (e.g., bottle size, headspace size, neck finish cross section, etc.), and environmental parameters, from which the corresponding machine and process parameters are algorithmically determined on a customer-specific basis. The algorithms are also continuously developed using laboratory measurements.

[0005] The product type parameters implemented within the control systems of these facilities are rigid and unresponsive to changes in the product or environment, potentially leading to filling problems. While it is possible for operators to manually parameterize the facilities, this requires highly specialized technical knowledge. Manual parameterization is often made more difficult by the fact that parameters are interdependent. For example, increasing the filling pressure results in longer depressurization times. In addition, inaccurate operation / parameterization of the facilities can ultimately lead to damage and high costs. [Prior art documents] [Patent Documents]

[0006] [Patent Document 1] European Patent Application Publication No. 3 495 911 Specification A1 [Patent Document 2] International Publication No. 2019 / 048051 A1 Pamphlet [Overview of the project] [Problems that the invention aims to solve]

[0007] The present invention aims to improve the control system of container handling equipment, preferably beverage filling equipment, and in particular to simplify its parameterization. [Means for solving the problem]

[0008] This objective is achieved by a method having the features of claim 1 and by a system having the features of claim 10. Further advantageous embodiments arise from the dependent claims, the following presentation of the invention, and the description of exemplary preferred embodiments.

[0009] A method according to the present invention is a method for controlling container handling equipment. The container handling equipment comprises at least one container handling station for handling containers and assigned control means for controlling the container handling process of the container handling station. The control means may be a component of the container handling station, or, for example, directly or indirectly assigned to it in the case of a higher-level equipment control system.

[0010] The container handling facility may include multiple container handling stations so as to enable multiple handling operations or handling steps to be performed on the containers. The container handling facility may include, for example, one or more of the following container handling stations: equipment for manufacturing containers; equipment for filling the containers with filled products; equipment for closing the containers using one container closure each; equipment for labeling the containers; equipment for inspecting the quality of the containers; buffers for temporarily buffering containers and for compensating for different processing / transportation speeds between parts of the facility; and packaging equipment for packaging the filled containers.

[0011] Particularly preferably, the container handling equipment is a beverage filling facility, and as a result, at least one of the container handling stations is a filling device configured to introduce a product into the container.

[0012] According to the present invention, real-time process data is sent from the control means to means for automatic process adjustment. The means for automatic process adjustment is preferably an external means, i.e., in this case, physically separated from the container handling equipment. The real-time process data can be obtained by corresponding sensors that monitor the container handling process. The real-time process data relates, for example, temperature, pressure, filling level, and the like. The real-time process data can also be obtained by one or more cameras, which are included here under the term "sensors".

[0013] The means for automatic process adjustment determines at least one process parameter by using, i.e., taking into account, the received real-time process data. The process parameter is used to control the container handling equipment or each of the container handling stations(s). Generally, the means for automatic process adjustment determines from the real-time process data several process parameters, such as the filling curve, pressure, pressurization and / or depressurization time, and the like, which will be set.

[0014] The at least one process parameter determined in this manner is written to the control means of each container handling station by the means for automatic process adjustment, resulting in adjustment of the container handling process.

[0015] Consequently, the expertise required for commissioning and operating the container handling equipment at its location is substantially reduced, as the equipment configuration and control are outsourced, at least partially, to the automated process adjustment system. The thus optimized container handling equipment can be configured particularly flexibly and operate in a more stable manner overall. Commissioning, product type changes, performance optimization, troubleshooting, etc., become substantially faster and safer. This also reduces the amount of training required and minimizes problems arising from personnel changes on the user side of the container handling equipment. Furthermore, centralized optimization helps reduce waste on the customer's side.

[0016] In addition, a centralized feedback loop is generated from the container handling equipment, along with associated processing procedures, enabling design based on actual values ​​in the field. This "feedback loop" accelerates product development and improvement on the manufacturer's side, as the flow of actual data from the field becomes available for equipment design, laboratory work, and new, further development.

[0017] The communication between the control means and the means for automatic process adjustment may be wireless or wired, digital or analog. This applies equally to all other electronic means described herein that communicate with each other, i.e., send and / or receive data / signals in at least one direction.

[0018] Preferably, the adjustment of the container handling process of the container handling station is brought about by the means for automatic process adjustment at regular time intervals, for example, every minute. In this way, it is possible to ensure particularly stable operation. In this case, the adjustment includes at least the determination of one or more process parameters by the means for automatic process adjustment and the writing of the determined process parameters to the control means. Reading of the real-time process data is not required, but can be done at the same frequency. Alternatively, or in addition to, the adjustment of the process can be triggered by an event. Such events can be triggered by the real-time process data, for example, when a threshold value is exceeded or not achieved, or by a change in the machine configuration.

[0019] Preferably, the control means includes or communicates with a human-machine interface ("HMI") module. The HMI module receives user inputs related to the container handling process, generates user data from them, and sends that data to the means for automatic process adjustment. The means for automatic process adjustment, in this case, takes the received user data into consideration when generating the process parameters or a set of process parameters, i.e., the process parameters depend on the user data. In this way, user inputs can be processed externally and incorporated into the operation of the equipment, which in turn can simplify the on-site control means, databases, algorithms, etc., thereby reducing the cost of acquiring and operating such container handling equipment, as well as contributing to the stability and flexibility of the equipment's operation.

[0020] The HMI module is preferably a portable means, such as a smartphone or tablet, so that the user can access desired information regardless of location.

[0021] The user data provided by the user or operator can be associated, for example, with information relating to the current state of the container handling equipment, such as defective products, ambient temperature, and the quality of filled products, and / or, for example, with a desired state in the case of a change in product type. For this purpose, the HMI module is preferably equipped with a user application that receives the user input in the most user-friendly manner possible. The complexity of the user application can be adapted to the operator's technical expertise and preferably presents the user with questions relating to the state and / or process behavior of the container handling equipment and / or at least one of its container handling stations, which are answered by the user, for example, via multiple choices, sequential text, or voice input.

[0022] Preferably, the real-time process data and / or user data received from the HMI module, which are sent to the means for automatic process adjustment, are also acquired by the development means. The development means uses this data to develop calculation rules for calculating process parameters or configuration data. As a result of the data feedback to the development means, the manufacturer can significantly simplify and accelerate product development and product improvement.

[0023] Thus, for example, calculation rules for product type parameters can be developed and / or optimized by the development means. These calculation rules receive, for example, product variables (degrees Brix, CO2 content, product temperature, etc.), container format variables (container volume, headspace volume, neck finish cross-section, container shape, container material, etc.), production capacity of the equipment, and the like as inputs, and calculate associated process parameters that can be stored as selectable configurations in the corresponding control means or used by the means for the automatic process adjustment. The above calculation rules can be optimized by a self-learning algorithm so that continuous optimization of the calculation rules and process parameters is possible as a result of the data feedback of the container handling equipment from practical applications. The term "calculation rules" in this case ranges from simple calculation formulas to complex algorithms.

[0024] Preferably, the means for the automatic process adjustment further receives configuration data from a configurator. The configuration data is used, for example, to determine the real-time process data that will be used to determine at least one of the process parameters and / or at least one optimization goal (filling machine performance, minimization of defective products, etc.). The configuration data is considered by the means for the automatic process adjustment for the purpose of determining the process parameters. In this way, it is possible to quickly and easily configure the means for the automatic process adjustment and thus indirectly the container handling equipment without involving the requirement that essential expertise must be available on-site.

[0025] Preferably, the at least one container handling station is a filling device for filling a filling product into a container. Possible filling products are, particularly preferably, beverages such as water (plain or carbonated), soft drinks, juices, beer, wine, dairy products, mixed drinks, and the like. Filling devices are complex from the point of view of their mechanical design, and their commissioning, configuration, etc. are almost never possible without thorough technical knowledge. Outsourcing to means for partial or complete (external) automatic process adjustment of these tasks is therefore particularly important in the case of beverage filling facilities that include filling devices.

[0026] In this case, the process parameters determined by the means for automatic process adjustment can include, for example, one or more of the following: filling pressure, pressurization time, pressurization pressure, filling rate, filling curve, decompression time, and / or tank pressure. Instead of or in addition to this, the real-time process data to be obtained can include information relating to one or more of the following variables: the Brix level of the filling product, the CO2 content of the filling product, the temperature of the filling product, the filling level, the volume of the headspace of the filled container.

[0027] The above-described object is achieved, in addition, by a system including a container handling facility, preferably a beverage filling facility, including at least one container handling station for handling a container, assigned control means for controlling the container handling process of the container handling station, and means for automatic process adjustment.

[0028] The means for automatic process adjustment receives real-time process data from the control means, preferably acquired by one or more sensors of the container handling equipment, and determines at least one process parameter taking into account, i.e., depending on, the received real-time process data, and writes the determined at least one process parameter to the control means, thereby assembling and configuring the container handling process of the container handling station to be adjusted.

[0029] The technical effects, advantages, and embodiments described above regarding the method are similarly applicable to this system as well.

[0030] Therefore, for the reasons stated above, an HMI module which is a component of the control means or communicates with it is preferably provided, the HMI module which is configured to receive user inputs relating to the container handling process, generate user data from them, and send the data to the means for automatic process adjustment, the means for automatic process adjustment which is configured in this case to determine the at least one process parameter, taking into further consideration the received user data. In this case, the HMI module is preferably a portable means such as a smartphone or tablet with an installed user application.

[0031] Preferably, for the reasons stated above, the system further includes development means configured to communicate with the means for automatic process adjustment, acquire the real-time process data sent to the means for automatic process adjustment and / or the user data received from the HMI module, and to develop calculation rules for calculating process parameters taking these into account, preferably by the use of a self-learning algorithm.

[0032] Preferably, for the reasons stated above, the system further includes a configurator configured to send configuration data to the means for automatic process adjustment, in which case the means for automatic process adjustment is configured to receive the configuration data and to determine the at least one process parameter taking the received configuration data into further consideration.

[0033] Preferably, for the reasons stated above, the at least one container handling station is a filling device for filling containers with products, particularly beverages.

[0034] In this case, the process parameters determined by the means for automatic process adjustment include one or more of the following: filling pressure, pressurization time, pressurization pressure, filling rate, filling curve, depressurization time, and / or tank pressure. For this purpose, the real-time process data to be obtained may include information relating to one or more of the following variables: the Brix level of the filled product, the CO2 content of the filled product, the temperature of the filled product, the filling level, and the headspace volume of the filled container.

[0035] Further advantages and features of the present invention will become apparent from the following description of preferred exemplary embodiments. The features described herein can be implemented individually or in combination with one or more of the features described above, provided that they do not conflict with each other. Preferred exemplary embodiments will now be described with reference to the accompanying drawings.

[0036] Hereinafter, preferred further embodiments of the present invention will be described in more detail with reference to the following drawings. [Brief explanation of the drawing]

[0037] [Figure 1] This diagram schematically represents a system having a beverage filling facility that includes a device for filling containers with a product, according to an exemplary embodiment. [Figure 2] This diagram schematically represents an apparatus for filling containers with a product, according to an exemplary embodiment. [Figure 3] An example of a filling curve is shown, which represents the filling rate as a function of time when a product is introduced into a container. [Figure 4] This diagram schematically illustrates the optimization of the filling process according to an exemplary embodiment. [Modes for carrying out the invention]

[0038] In the following, preferred exemplary embodiments will be described with reference to the drawings. In these drawings, elements having the exact same, similar, or equivalent effect are indicated by the exact same reference numerals, and in some cases, the description of those elements will not be repeated to avoid redundancy.

[0039] Figure 1 shows a schematic representation of a system having a beverage filling facility 1 that includes multiple container handling stations. The beverage filling facility 1 is an example of a container handling facility, and in this case, at least one of the container handling stations is a device 20 for filling containers (not shown in Figure 1) with products, particularly beverages.

[0040] According to this exemplary embodiment, the beverage filling facility 1 comprises the following container handling stations: a device 10 for manufacturing containers, also referred to here as the “container manufacturing device”; a device 20 for filling containers with products, also referred to here as the “filling device”; a device 30 for closing each container with a container closure, such as a crown cork or screw cap, also referred to here as the “lid closing device”; a device 40 for labeling containers, also referred to here as the “labeling device”; a buffer 50 for temporarily buffering filled and labeled containers and to compensate for different processing / transportation speeds between parts of the facility; a packaging device 60 for packaging containers; a robot 70 for creating layers; and a palletizer 80 for palletizing packaged containers onto a cargo carrier.

[0041] The beverage filling facility 1 thus comprises one or more container handling stations through which containers pass continuously, for example, from the manufacture of containers to their filling, lid sealing, labeling, and packaging. For this purpose, containers, or their preforms in the preliminary stages of containers before blow molding or stretch blow molding, are transported along a conveyor route. Transport is brought about using conveyor staircases, conveyor belts, and the like, which are schematically represented in part in Figure 1. Preforms, containers, container closures, and holders / clamps configured for them are not shown in Figure 1 for reasons of clarity. Transport means such as conveyor staircases or conveyor belts may be used alone for transport, or appropriate handling elements may be equipped at the processing stations.

[0042] The container handling station of the beverage filling facility 1 shown in Figure 1 is merely illustrative. The container handling facility or beverage filling facility 1 can therefore be equipped with further or alternative container handling stations, such as cleaning equipment, inspection equipment for quality assurance, for example, to check whether foreign particles are present in filled containers, and the like. Similarly, stations such as container manufacturing equipment 10, buffers 50, packaging equipment 60, and / or others can be omitted, for example, when containers are delivered in their final form to be filled.

[0043] The container manufacturing apparatus 10 has means 11 for preparing and preheating a premolded product made of plastic, preferably PET. The premolded product thus prepared is transferred to a blow molding means 12, where the heated premolded product is expanded by blow or stretch blow to form a container to be filled. For this purpose, in order to bring the premolded product to the desired container shape, the premolded product is supplied with pressurized gas in a blow mold in which the contour of the cavity corresponds to the outer shape intended for the container, and in the case of stretch blow, it is expanded using a stretch rod / stretch bar. The container manufacturing apparatus 10 may further include apparatus for cleaning, sterilizing, and / or coating the container, although not shown herein.

[0044] The containers produced in this manner are transferred to the filling device 20. In the exemplary embodiments shown in Figures 1 and 2, the filling device 20 is based on a rotary design. For this purpose, the device includes a filling carousel 21 with a number of filling elements (not shown in Figure 1) on its outer circumference, configured to introduce the filling product into the containers. The filling device 20 may include, for example, a mixer 20a configured to produce a multi-component filling product by mixing syrup into a flow of drinking water.

[0045] After filling, the containers are transferred to a lid-closing device 30, which can also be designed to rotate. For this purpose, the lid-closing device 30 includes a lid-closing carousel 31 with a number of lid-closing elements (not shown in Figure 1) on its outer circumference, each configured to close the filled containers using a container closure.

[0046] The transfer of filled containers from the filling device 20 to the lid-closing device 30 can be done directly from the filling carousel 21 to the lid-closing carousel 31, or using one or more transfer steers. Alternatively, the filling device 20 and the lid-closing device 30 can be integrated to form a filling / lid-closing machine where the filling and lid-closing processes are performed at different handling angles on a single, identical handling carousel.

[0047] An exemplary apparatus 20 for filling a container 100 with a filled product is schematically shown in Figure 2.

[0048] In the exemplary embodiment shown in Figure 2, the filling device 20 includes a filling valve 23 that introduces the product to be filled into the container 100 through a valve opening 23a. Possible products to be filled are preferably beverages, such as water (plain or carbonated), soft drinks, juices, beer, wine, dairy products, mixed alcoholic beverages, and the like.

[0049] Throughout the filling process, the neck finish 110 of the container 100 is preferably in consolidation contact with the filling valve 23, allowing the filling process to be carried out as a counter-pressure or negative-pressure process. However, the filling valve 2 can also be embodied as a free-jet valve so that the product to be filled is filled into the neck finish 110 of the container 100 after it has passed through the free-jet region. Furthermore, the filling process and, where appropriate, the subsequent lid closing of the container 100 can be brought into a consolidated and vacuum-tight handling chamber (not shown in the figure) that allows for the provision of a defined atmosphere with a defined pressure to counteract the tendency of the product to foam, or to close the container 100 in a defined gas atmosphere and / or under negative or gauge pressure.

[0050] During filling, the container 100 to be filled is held by a container holder 24 on or below the filling valve 23. The container holder 24 preferably has a retaining clamp 24a for holding the container 100 in the neck region, for example, directly below the neck ring of the container 100, although this is not shown herein. This is also called “neck handling” of the container 100. “Neck handling” is used in particular for filling plastic containers in the form of PET bottles. In alternatives not shown in the figures, the container 100 to be filled may also be held or supported in its base region, for example, by a guide plate on which the container 100 stands. This is also called “base handling” of the container 100. “Base handling” is used in particular for filling glass bottles. Similarly, in alternatives not shown in the figures, the container 100 to be filled may be held and / or supported in the region of the container body or the belly of the bottle, or held and / or supported in another suitable manner and transported.

[0051] Particularly preferably, the filling valve 23 is embodied as a proportional valve 23b positioned before the valve opening 23a, i.e., upstream of the valve opening 23a, or encompasses it. Optionally, a shut-off valve is provided within the region of the valve opening 23a to open / close the valve opening 23a as needed. The proportional valve 23b is configured to vary the volumetric flow rate of the filling product and thus regulate the amount of filling product introduced into the container 100 per unit time. The aim is to ensure efficient, accurate, and product-saving filling along a predefined filling curve, which is generally a time-dependent function of the filling rate or volumetric flow rate.

[0052] The proportional valve 23b can be assembled in such a way that the annular gap through which the filled product flows can be changed in its dimensions. The operating position of the proportional valve 23b, and therefore the size / dimension of the currently switched annular gap, can be set in a manner that is known and reproducible, for example, by using a stepper motor to drive the proportional valve 23b.

[0053] The proportional valve 23b can be used to define one or more characteristics of the filling curve (see Figure 3), such as the end of filling when a desired filling level is reached, or the entire filling curve.

[0054] The filled product is temporarily stored in a filled product reservoir 25 before it is actually filled into the container 100 to be filled, where the filled product reservoir 25 is shown in the form of a central tank of a rotary filling machine. In an alternative embodiment, the filled product reservoir 25 may also be embodied in the form of a ring tank, a ring line, or a distributor supply port.

[0055] Within the filled product reservoir 25, the filled product is filled to a specific filling level, from which it can flow to the filling valve 23 via the filled product line 26, which here has an exemplary first line section 26a, a second line section 26b, a third line section 26c, and a fourth line section 26d, and from there into the container 100 to be filled.

[0056] In addition to the proportional valve 23b for controlling or regulating the flow of the filled product, a flow meter 27 is further provided, configured to detect the amount of fluid or volumetric flow rate of the filled product flowing through the filled product line 26. Using the flow meter 27, if necessary, the amount of filled product to be introduced into the container 100 can also be determined, for example, by the integration or sum of the determined volumetric flow rates. After the filled product in the container 100 has reached the desired level, the filling process can be terminated by closing the proportional valve 23b and / or by closing a shut-off valve not shown herein. Other sensors, such as load cells and / or short-circuit probes, can be used as an alternative to the flow meter 27. Alternatively, sensors can be omitted, for example, if a time-based filling process based on a calculation model for determining the volumetric flow rate is used.

[0057] The filling valve 23, including the proportional valve 23b, the flow meter 27, and the sections of the filling product line 26, such as line sections 26b, 26c, and 26d, can form a conceptual and / or structural unit, or component, which here shall be referred to as the filling element 22.

[0058] The filling apparatus 20 shown in Figure 2 shows only one filling element 22 that is fluidly connected to the product reservoir 25. However, preferably, the filling apparatus 20 has a number of filling elements 22 arranged, for example, around a common product reservoir 25 and on the outer circumference of a filling machine carousel 21 (see Figure 1), thereby forming a rotary filling machine. The filling machine carousel 21 rotates around a rotation axis R, as schematically shown, to fill containers 100 during rotation and simultaneously transport them along a circular orbit. For example, there may be 20 or more filling elements 22 arranged around the filling machine carousel 21 so that a flow of containers 100 to be filled is supplied to the rotary filling machine and filling can be performed in an efficient manner.

[0059] The filling apparatus 20 may include one or more filters 28 as part of the filling element 22 or outside of it, preferably positioned between the first section 26a and the second section 26b of the filling product line 26. The filters 28 are configured to clean the filling product before filling in order to filter out particles, viruses, bacteria, fungi, etc. from the filling product.

[0060] The current filling level of the filled product in the filled product reservoir 25 can be measured, for example, using a filling level probe 25a.

[0061] The filling device 20 further includes a filling machine control system 29 configured to communicate with the filling element 22. In particular, the filling machine control system 29 communicates with the proportional valve 23b, the filling level probe 25a, and the flow meter 27 to define the current operating position of the proportional valve 23b using a volumetric flow rate value determined by the flow meter 27. Furthermore, the filling level in the filling product reservoir 25 can also be evaluated using the filling machine control system 29. The filling level probe 25a and the flow meter 27 are, for example, sensors for monitoring the filling process.

[0062] Referring back to Figure 1, other container handling stations can also be equipped with corresponding control means; for example, a container manufacturing control system 19 and a lid closing control system 39 are shown. These individual control means 19, 29, and 39 can be implemented centrally or distributed in any other way, as components of an internet-based and / or cloud-based application, and can also access a database if necessary. Communication between the control means 19, 29, and 39, and / or with a higher-level equipment control system 9, and / or with the components to be controlled and the sensors to be read, can be wireless or wired, digital or analog. Furthermore, the control means 9, 19, 29, and 39 do not need to be implemented by separate means, but can be partially or completely integrated.

[0063] The equipment control system 9 can be embodied, for example, as an LMS (Line Management System) that monitors and / or controls various stations of the beverage filling equipment 1 via communication with subordinate station-specific control means 19, 29, 39.

[0064] The filling machine control system 29 (potentially operating in combination with the equipment control system 9) is configured to control the filling elements 22 of the filling device 20 in such a manner that the filling product is introduced into the container 100 in a desired quantity and at a desired rate. For this purpose, there may be one or more sets of process parameters, such as pressure, depressurization time, and the like, that specify the process behavior of the filling device 20, stored in the filling machine control system 29 or the system control system 9. These sets of parameters are generally preset and can also be assigned, for example, to different types of filling products to be filled.

[0065] In the simplest case, the filled product is introduced into the container 100 at a constant flow rate or a constant volumetric flow rate. A more complex, exemplary filling curve K is shown in Figure 3, where the flow rate as the filled product is introduced into the container 100 is expressed as a function of time. According to this exemplary embodiment, the filling curve K can be divided into three sections KA, KB, and KC.

[0066] In section KA of the filling curve at the start of the filling operation, a main flow rate, e.g., 170 ml / second, is applied until a specific amount, e.g., 795 ml, is present in container 100. Then, in section KB of the filling curve, the flow rate is reduced to a final flow rate, e.g., 100 ml / second. This final flow rate is reached at a filling volume of, e.g., 890 ml. This final flow rate is then used in section KC of the filling curve until the desired filling volume, e.g., 1000 ml, is reached and filling is complete. This provides the filling time in rated operation.

[0067] The actual shape of the filling curve K may depend on the product to be filled, the container format (size, geometry, material, etc.), the output of the filling machine, and other variables. Commissioning of the beverage filling equipment 1, changing the product type, changing the container format, or similar actions are brought about, for example, by the operator selecting a previously created configuration in the menu of the HMI module 9a ("Human-Machine Interface Module") (see Figure 1). The HMI module 9a may be part of or communicate with the equipment control system 9. Alternatively, or in addition to that, the HMI module 9a may also communicate with one or more of the dependent control means 19, 29, 39. The HMI module 9a may be a mobile communication means, such as a tablet or smartphone.

[0068] Of the selected configurations, process parameters (filling pressure, pressurization time, filling curve, etc.) are stored in the equipment control system 9 and / or control means 10, 29, 39 as data records used to control the beverage filling equipment 1.

[0069] One of the equipment control system 9 and / or subordinate control means 19, 29, 39 communicates with electronic means 200 for automatic process adjustment of the beverage filling equipment 1. Means 200, also referred to here as “process adjustment means,” is, for example, an external control system within the manufacturer’s access range for the container handling equipment or beverage filling equipment 1.

[0070] The process adjustment means 200 calculates adjusted process parameters from real-time process data of the beverage filling equipment 1, such as sensor data, input from operators, camera recordings, etc., and preferably periodically, for example every minute, writes them to the subordinate control means 19, 29, 39 of the equipment control system 9 and / or the corresponding container handling stations, enabling the processing operation to be adjusted in real time for any changes. In this case, it is possible to directly override a predefined set of process parameters, or alternatively, process parameters generated / optimized by the process adjustment means 200 are written to another location and read from there and used by the corresponding control means 9, 19, 29, 39.

[0071] With respect to the filling apparatus 20, the process adjustment means 200 can calculate process parameters such as filling pressure, pressurization time, filling rate, filling curve K, pauses (one or more), and depressurization time (one or more) from real-time process data, and can modify them if necessary.

[0072] Alternatively, or in addition to the above, the adjusted process parameters calculated by the process adjustment means 200 can be optimized taking into account the operator's input to the HMI module 9a. For this purpose, the HMI module 9a may be equipped with a user application 9b (see Figure 4) that sends operator input or data derived therefrom to the process adjustment means 200. Preferably, the user application 9b is configured to present the operator with questions relating to the status and / or process behavior of the beverage filling equipment 1 and / or one or more container handling stations, such as the filling device 20. These questions are answered by the operator, for example, through multiple choices, continuous text, voice input, or another appropriate means.

[0073] The optimization of process parameters, with the assistance of user applications 9b, which is transmitted to the process adjustment means 200 via the HMI module 9a, has the advantage of substantially reducing the expertise required at the location of the beverage filling equipment 1 for commissioning, product type changes, troubleshooting, etc. Centralized data feedback to the process adjustment means 200, preferably located with the manufacturer, simplifies and stabilizes the operation of the beverage filling equipment 1. In addition, fewer product types, container formats, etc., can be pre-configured within the equipment control system 9 or subordinate control means 19, 29, 39, which further simplifies the operation and handling of the beverage filling equipment 1.

[0074] Optimization initiated via real-time process data and / or user application 9b sent to process adjustment means 200 is also obtained and can be used to develop calculation rules (formulas, algorithms, etc.) for obtaining process parameters to control beverage filling equipment 1. For this purpose, development means 300 can be provided, which communicates with or is a component of process adjustment means 200, and is configured to generate and / or optimize calculation rules for determining process parameters from optimization initiated via real-time process data and / or user application 9b. The development means 300 can therefore develop and / or optimize calculation rules for, for example, product type parameters of filling equipment 20. These calculation rules take product variables (Brix level, CO2 content, product temperature, etc.), container format variables (container volume, headspace volume, neck finish cross section, container shape, neck finish shape, container material, etc.), equipment outputs, and similar types as inputs, and calculate associated process parameters that are stored in the equipment control system 9 and / or corresponding control means 19, 29, 39 as selectable configurations, or used automatically by the corresponding control means 9, 19, 29, 39. In practice, the above calculation rules can be optimized by a self-learning algorithm, including the optimization of the calculation rules themselves in a continuous and largely automated manner, so that the process parameters can be derived from data feedback from the beverage filling equipment 1.

[0075] Figure 4 shows a schematic block diagram of the optimization of the filling process according to an exemplary embodiment.

[0076] In this example, the process adjustment means 200 acquires real-time process data from the container manufacturing control system 19 and the filling machine control system 29 for the purpose of automatic process adjustment. The real-time process data recorded by sensors, cameras, etc., includes, for example, the current filling level, product quality (Brix level, CO2 content, etc.), over-foaming tendency, flow-through measurement, pressure, and the like.

[0077] The process adjustment means 200 further relates configuration data that constitutes the processing operation of the process adjustment means 200, which determines, for example, which real-time process data to use in optimization and what optimization goals (such as filling machine performance or minimizing defective products) they should be processed toward. The configuration data may be generated as a result of user input from the HMI module 9a, or may take it into consideration.

[0078] The process adjustment means 200 is equipped with, for example, an inspection section 210 for inspecting the quality of received data, a programmable logic section 220 for computing operations, and an error handling section 230 for error correction and / or reporting. From the inputs from the container manufacturing control system 19, the filling machine control system 29, the configurator 400, and the HMI module 9a, the process adjustment means 200 calculates the process parameters used to control the filling machine 20. Focusing on the filling machine 20, the following process parameters can be set automatically, for example: filling pressure, pressurizing time, pressurizing pressure, filling rate, filling curve, depressurization time, and / or tank pressure. The process parameters thus optimized can be assigned to product types or structured in another way. Furthermore, the calculated process parameters can be used directly to control the filling machine, or those process parameters can be written to the corresponding control means, thereby influencing the handling process. Process parameters optimized for controlling the filling device 20 can be saved for subsequent use, for example, in local storage or cloud storage 500.

[0079] Optimization by the process adjustment means 200 can occur at regular intervals, for example every minute, and / or be triggered by events. Such events can be triggered, for example, by real-time process data, such as when a threshold value is exceeded or not achieved, or by changes in configuration data.

[0080] The optimization of the filling process can be achieved or be different from each other at different levels, separated logically, spatially, or otherwise. Thus, while the container manufacturing control system 19, the filling machine control system 29, the filling device 20, and the corresponding sensor technology for acquiring real-time process data are components of the beverage filling facility 1, the process adjustment means 200 for automatic process adjustment, the configurator 400, the HMI module 9a with user application 9b, and the cloud storage 500 can be located elsewhere, i.e., physically separated from the beverage filling facility 1.

[0081] As an example, the schematic block diagram in Figure 4 is limited to the real-time optimization of the filling unit 20. However, it is clear that the processing of container handling equipment or alternative or additional container handling stations of the beverage filling equipment 1 can be optimized in a similar manner. Furthermore, additional or alternative real-time process data can also be used for optimization.

[0082] The equipment, optimized in this way, operates in a substantially more stable manner overall. Commissioning, product type changes, troubleshooting, etc., are substantially faster and safer.

[0083] The expertise required for commissioning and reliable operation of beverage filling equipment 1 at its location is substantially reduced because the equipment configuration and control are outsourced, at least partially, to external means. This reduces the amount of training required and minimizes problems that may arise when there are personnel changes on the user side of beverage filling equipment 1. Centralized optimization helps reduce defective products on the customer side.

[0084] Centralized data feedback and associated processing from beverage filling equipment 1 are implemented, enabling design based on actual values ​​in the field. This "feedback loop" accelerates product development and improvement on the manufacturer side, as the flow of real data from practical applications becomes available for equipment design, laboratory work, and new and further development.

[0085] To the extent applicable, all individual features represented within the exemplary embodiments can be combined with and / or interchanged with one another without departing from the scope of the invention. [Explanation of Symbols]

[0086] 1. Container handling equipment 9. Equipment Control System 9a HMI module 9b User Applications 10 Apparatus for manufacturing containers 11. Means for preparing and preheating premolded parts 12. Blow molding means 19. Container Manufacturing Control System 20. Apparatus for filling products into containers. 20a Mixer 21 Filling machine carousel 22 Filling elements 23 Filling valve 23a Valve opening 23b Proportional valve 24 Container holder 24a Holding clamp 25 Filled product reservoir 25 Filling level probe 26 Filling Product Line 26a First section of the filling product line 26b Second section of the filling product line 26c Third section of the filling product line 26d Fourth section of the filling product line 27 Flow meter 28 filters 29. Filling Machine Control System 30. Device for closing a container 31. Carousel with lid closed 39. Lid Closing Control System 40. Apparatus for labeling containers 50 buffers 60 Packaging equipment 70 Robots 80 Palletizers 100 containers 110 Container neck finish 200 Means for automatic process adjustment 210 Inspection Section 220 Logic Section 230 Error Handling Section 300 Development Methods 400 Configurator 500 Cloud Storage R axis of rotation K filling curve Section of the KA filling curve KB Filling curve section KC Filling curve section

Claims

1. A method for controlling a container handling installation (1), preferably a beverage filling installation, comprising at least one container handling station (10, 20, 30, 40, 50, 60, 70, 80) for handling containers (100) and assigned control means (9, 19, 29, 39) for controlling the container handling process of said container handling station (10, 20, 30, 40, 50, 60, 70, 80), comprising: - transmitting real-time process data from said control means (9, 19, 29, 39) to a means for automatic process regulation (200), said real-time process data being preferably acquired by one or more sensors (25a, 27) of said container handling installation (1); determining, by the means for automatic process adjustment (200), at least one process parameter depending on the received real-time process data; - writing said determined process parameters into said control means (9, 19, 29, 39) resulting in the adjustment of said container handling process of said container handling stations (10, 20, 30, 40, 50, 60); The method includes:

2. 2. The method according to claim 1, characterized in that the adjustment of the container handling process of the container handling stations (10, 20, 30, 40, 50, 60), which comprises at least the determination of one or more process parameters by the means for automatic process adjustment (200) and the writing of the determined process parameters to the control means (9, 19, 29, 39), is effected at regular time intervals, preferably about every minute.

3. 3. The method according to claim 1 or 2, characterized in that the control means (9, 19, 29, 39) comprises or communicates with an HMI module, the HMI module (9a) receiving user inputs related to the container handling process, generating therefrom user data and sending said data to the means for automatic process adjustment (200), the means for automatic process adjustment (200) receiving the user data and determining the at least one process parameter dependent thereon.

4. 4. The method according to claim 3, characterized in that the HMI module (9a) is a portable means, preferably a smartphone or a tablet.

5. 4. The method according to claim 3, characterized in that the HMI module (9a) has installed thereon a user application (9b) which receives the user input, and the user application (9b) presents the user with questions, preferably related to the status and / or process behavior of the container handling installation (1) and / or of at least one container handling station (10, 20, 30, 40, 50, 60) thereof, and that the questions are answered by the user, preferably via multiple choice, continuous text or voice input.

6. 2. The method according to claim 1, characterized in that the real-time process data sent to the means for automatic process adjustment (200) and / or the user data received from the HMI module (9a) are acquired by development means (300) and used for developing calculation rules for calculating process parameters, and that the calculation rules are preferably generated and / or optimized by means of a self-learning algorithm.

7. 2. The method of claim 1, characterized in that the means for automatic process adjustment (200) also receives configuration data from a configurator (400) and further determines the at least one process parameter in dependence on the configuration data, and that the configuration data determines the real-time process data, which will preferably be used for determining the at least one process parameter and / or at least one optimization goal.

8. 2. The method according to claim 1, characterized in that said at least one container handling station (10, 20, 30, 40, 50, 60) is a filling device (20) for filling containers (100) with a filled product, preferably a beverage.

9. The at least one process parameter includes one or more of the following: fill pressure, pressurization time, pressurization pressure, fill rate, fill curve (K), depressurization time, and / or tank pressure; and / or the real-time process data includes variables: brix level of the filled product, CO2 of the filled product, ２ 9. The method of claim 8, including information related to one or more of the content, temperature of the filled product, fill level, and headspace volume of the filled container (100).

10. A system including a container handling installation (1), preferably a beverage filling installation, including at least one container handling station (10, 20, 30, 40, 50, 60, 70, 80) for handling containers (100), assigned control means (9, 19, 29, 39) for controlling the container handling process of said container handling station (10, 20, 30, 40, 50, 60, 70, 80), and means (200) for automatic process regulation, said means (200) being: receiving real-time process data from said control means (9, 19, 29, 39), preferably acquired by one or more sensors (25a, 27) of said container handling installation (1); determining at least one process parameter dependent on the received real-time process data; and The system is configured to write the determined process parameters to the control means (9, 19, 29, 39), as a result of which the container handling process of the container handling stations (10, 20, 30, 40, 50, 60) is adjusted.

11. 11. The system according to claim 10, further comprising an HMI module (9a) which is a component part of or in communication with said control means (9, 19, 29, 39), said HMI module (9a) configured to receive user inputs related to the container handling process, generate therefrom user data and send said data to said means for automatic process adjustment (200), said means for automatic process adjustment (200) configured to determine said at least one process parameter further dependent on said received user data, and said HMI module (9a) is preferably a portable means.

12. The system according to claim 10 or 11, characterized in that it further comprises development means (300) in communication with the means for automatic process adjustment (200) and configured to acquire the real-time process data sent to the means for automatic process adjustment (200) and / or the user data received from the HMI module (9 a) and to develop calculation rules for calculating process parameters depending thereon, preferably by use of a self-learning algorithm.

13. 11. The system of claim 10, further comprising a configurator (400) configured to send configuration data to the means (200) for automatic process adjustment, the means (200) configured to receive the configuration data and determine the at least one process parameter further depending on the received configuration data.

14. 11. The system according to claim 10, characterized in that said at least one container handling station (10, 20, 30, 40, 50, 60) is a filling device (20) for filling containers (100) with a filling product, preferably a beverage.

15. The at least one process parameter includes one or more of the following: fill pressure, pressurization time, pressurization pressure, fill rate, fill curve (K), depressurization time, and / or tank pressure; and / or the real-time process data includes variables: brix level of the filled product, CO2 of the filled product, ２ 15. The system of claim 14, including information related to one or more of the content, temperature of the filled product, fill level, and headspace volume of the filled container (100).

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