Cross-Process Sensor Evaluation for Packaging Quality Assurance
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Solution Overview
Problem
Industrial automated processes, such as weighing, filling, and packaging, face challenges in ensuring process quality due to various influencing factors across sub-processes, which often go undetected and lead to reduced quality in the overall process result, making it time-consuming and complex to evaluate and secure the load effectively.
Innovation Solution
A device and system that includes sensors to detect process-relevant parameters, a processing unit for data evaluation, and an interface for data transmission across sub-processes, allowing for the comparison of process data values with predefined specifications to ensure quality control and load safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional sub-process evaluation methods are used, then each sub-process can be evaluated independently, but the overall process quality cannot be adequately assessed and deviations affecting the entire process remain undetected
Solution Approach 1:
The patent implements a universal evaluation approach where a single process data value serves multiple purposes: it evaluates the current sub-process, predicts downstream sub-process quality, and identifies upstream deviations. This multi-functional use of process data values enables comprehensive process quality assurance without requiring separate evaluation systems for each sub-process, thus improving reliability while managing complexity.
Solution Approach 2:
The patent establishes feedback loops where process data values from downstream sub-processes are used to evaluate upstream sub-processes. When a deviation is detected in a downstream sub-process, the system traces back to identify the originating upstream sub-process, creating a feedback mechanism that enables continuous improvement and prevents recurrence of quality issues.
2Reliability
If comprehensive process monitoring is implemented across all sub-processes, then overall process quality can be improved, but the system becomes time-consuming and complex to operate
Solution Approach 1:
The patent extracts only the most critical process data values that have impact across multiple sub-processes, rather than monitoring all possible parameters. By identifying and focusing on key process data values that serve as indicators for overall process quality, the system achieves comprehensive monitoring without the time and complexity burden of exhaustive monitoring of every parameter in every sub-process.
Solution Approach 2:
The patent performs preliminary evaluation by comparing process data values against predetermined tolerance ranges before downstream deviations occur. This proactive approach allows the system to identify and address potential quality issues in upstream sub-processes before they manifest as problems in downstream sub-processes, reducing the need for time-consuming reactive investigations.
3Measurement precision
If detailed monitoring of all process parameters is performed, then measurement precision is improved, but the complexity of detecting and measuring all influences increases
Solution Approach 1:
The patent applies local quality by assigning different levels of monitoring precision to different process parameters based on their impact on overall process quality. Critical process data values that affect multiple sub-processes are monitored with high precision, while less influential parameters are monitored with lower precision or not at all. This selective approach maintains measurement precision for critical parameters while reducing the overall difficulty of detection and measurement.
Data Source
Figure 1
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AI summary
The invention relates to a device (10) for at least one industrial automated process (110), in particular a weighing and/or packing and/or arranging and/or packing process, comprising: at least one sensor (30) for determining at least one process data value which is relevant to the entire process by detecting at least one partial process parameter of the device (10), which parameter is relevant to the entire process, a processing device (40), which is electrically connected to the sensor (30) for processing the process data value, an interface device (50) for data connection and for forwarding the process data value to at least one individual machine (2a, 2b, 2c) located upstream and/or downstream in the process (110), wherein the total process (110) can be evaluated with reference to the process data value by comparison with a pre-defined process instruction (130).