Container Handling Plant Control via Real-Time Data Feedback

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Solution Overview

Problem

Existing container handling plants, particularly in the beverage filling industry, face challenges with rigid product type parameters that do not adapt to changes, requiring specialized knowledge for manual parameterization and leading to potential damage and high costs due to interdependent parameters.

Innovation Solution

Implementing a system with real-time process data feedback for automatic process adjustment, using sensors and an external means to determine and adjust process parameters such as filling curves and pressures, reducing the need for on-site expertise and enabling flexible and stable operation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If manual parameterization is used by operators, then the plant can be adjusted to different product types, but highly specialised technical knowledge is required and the process becomes complex and error-prone

Engineering Contradiction:

Improveadaptability to product changesVSAvoidease of parameterization

Core Design Contradiction:

Adaptability or versatilityVSEase of operation

Solution Approach 1:

The control system automatically determines machine and process parameters by receiving product-specific parameters and container-specific parameters as input, then autonomously calculating the optimal settings without requiring operator intervention. This self-service approach eliminates the need for highly specialised technical knowledge while maintaining adaptability to different product types.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent replaces manual mechanical parameterization with an automated computational system. Instead of operators manually adjusting parameters based on experience and knowledge, the system uses algorithms to automatically calculate optimal parameters based on input data about products and containers.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If rigid product type parameters are implemented in the control system, then the filling process can be controlled, but the parameters do not respond to product changes or environmental changes resulting in filling problems

Engineering Contradiction:

Improvestability of filling processVSAvoidresponsiveness to changes

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The control system transitions from static, pre-programmed parameters to dynamic parameter determination. The system continuously receives current product-specific and container-specific parameters and automatically calculates optimal machine and process parameters in real-time, allowing the filling process to adapt dynamically to product changes and environmental conditions while maintaining stability.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system implements a feedback mechanism where the actual product characteristics and container properties are continuously measured and fed back to the control algorithm. This feedback loop enables the system to adjust parameters in response to actual conditions, ensuring both reliability and adaptability.

Inventive Principle:

Principle #23Feedback

3Productivity

If interdependent parameters are manually adjusted, then the filling process can be optimized, but incorrect operation can result in damage and high costs

Engineering Contradiction:

Improveoptimization of filling processVSAvoidrisk of damage

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The control system autonomously determines optimal parameter combinations by receiving product and container specifications and automatically calculating the appropriate machine and process parameters. This eliminates manual adjustment errors and the associated risks of damage, while still achieving process optimization through algorithmic calculation of optimal settings.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The system performs preliminary calculations to determine safe and optimal parameter settings before the filling process begins. By pre-calculating the correct parameter combinations based on product and container characteristics, the system prevents harmful operations before they can occur, cushioning against potential damage.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Data Source

PatentUS20240317562A1Method and system for controlling a container handling plant

Publication Date: 2024.09.26 KRONES AG

AI summary

Methods for controlling a container handling plant, for example a beverage filling plant, including at least one container handling station for handling containers, and an assigned control means for controlling a container handling process of the container handling station, the method including: sending real-time process data from the control means to a means for automatic process adjustment, the real-time process data in some embodiments being acquired by one or more sensors of the container handling plant; determining at least one process parameter, by the means for automatic process adjustment, in dependence on the received real-time process data; and writing the determined process parameter to the control means, resulting in adjustment of the container handling process of the container handling station.