Production Line Container Tracking for Cross-Machine Process Control

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Solution Overview

Problem

Existing production line control systems can only perform error analysis for individual machines, leading to inadequate and fragmented optimization of the production process.

Innovation Solution

A method to control a production process with serially connected production processes by individually assigning data records to containers throughout the production process and enriching them with process- and container-specific production data, using a monitoring system that includes both shift registers and imaging transport tracking.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of repair

If individual machine error analysis is performed, then troubleshooting for specific machines is facilitated, but comprehensive optimization of the production line is inadequate

Engineering Contradiction:

Improvetroubleshooting for specific machinesVSAvoidproduction line optimization

Core Design Contradiction:

Ease of repairVSProductivity

Solution Approach 1:

The patent combines individual machine data records into a unified production line data structure. Each container's data record aggregates information from multiple process units (blow molding, filling, capping, labeling) along the entire production line, enabling both individual machine analysis and comprehensive line-wide optimization simultaneously.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The unified data record structure serves multiple functions: it tracks individual container history through all process units, enables error analysis for specific machines, supports production line optimization, and provides a basis for predictive maintenance across the entire production system.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Measurement precision

If data records are tracked through shift registers in forced guidance transport, then container identification is achieved, but transport section limitations reduce system versatility

Engineering Contradiction:

Improvecontainer identificationVSAvoidtransport section compatibility

Core Design Contradiction:

Measurement precisionVSAdaptability or versatility

Solution Approach 1:

The monitoring system is designed to work with multiple transport types (forced guidance with shift registers, free-flow with imaging systems, air transport with runtime monitoring) through a unified data record structure, making the system universally applicable across different transport configurations without sacrificing identification precision.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent introduces intermediate tracking zones where containers transition between different transport types. Imaging systems in these intermediate zones serve as mediators that bridge forced guidance and free-flow transport, ensuring continuous container identification and data record assignment across transport boundaries.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Measurement precision

If imaging transport tracking is used for unordered mass transport, then container tracking is achieved, but system complexity increases

Engineering Contradiction:

Improvecontainer tracking in mass transportVSAvoidtracking system complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent uses imaging systems to create visual copies of container identification marks, which are then processed and assigned to data records. This copying approach enables tracking of containers in unordered mass transport without requiring physical manipulation or complex mechanical tracking mechanisms.

Inventive Principle:

Principle #26Copying

Solution Approach 2:

The patent replaces mechanical tracking systems (shift registers, physical position encoders) with imaging-based optical systems for container identification. This substitution reduces mechanical complexity while maintaining tracking precision in free-flow and air transport configurations.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Measurement precision

If runtime monitoring is used for air transport with first-in-first-out, then container tracking is achieved, but production output constancy requirement limits flexibility

Engineering Contradiction:

Improvecontainer tracking in air transportVSAvoidproduction output flexibility

Core Design Contradiction:

Measurement precisionVSAdaptability or versatility

Solution Approach 1:

The system assigns data records to containers at the entrance of air transport sections before the actual transport occurs. This preliminary assignment, based on runtime monitoring and container position, enables tracking flexibility without requiring strict constancy of production output throughout the transport process.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentEP4563521A1Method for controlling a production process in a production line and production line, in particular a filling line

Publication Date: 2025.06.04 KRONES AG

Figure 1

AI summary

A method is described for controlling a production process with at least two serially connected production processes for the manufacture and/or processing of containers in a production line that includes, precedes, or follows the filling of liquid products, as well as a corresponding production line. Accordingly, data records are individually assigned to the containers throughout the production process. As the data records are processed through the production processes, they are enriched with process- and/or container-specific production data. This allows the production line to be comprehensively optimized by tracing individual process steps and process results.