Labeling Machine Consumable Monitoring via Predictive Remaining Time
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Solution Overview
Problem
In labeling machines, the simultaneous monitoring of multiple consumables such as glue and labels is inefficient, leading to production interruptions and high personnel requirements due to coinciding signals and unsatisfactory reaction times, as existing methods primarily rely on monitoring reserve thresholds rather than continuous consumption patterns.
Innovation Solution
A method and device for continuous monitoring of consumable supplies in labeling machines, using sensors like capacitive and distance sensors to measure fill levels and calculate glue consumption, enabling prediction of remaining running times and optimizing production planning by determining time profiles of consumable storage units.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If continuous monitoring of multiple consumables is implemented, then production interruptions are reduced, but device complexity increases
Solution Approach 1:
The patent combines multiple monitoring functions (fill level detection, consumption rate calculation, remaining time prediction) into a single integrated monitoring system. The control unit centrally processes data from multiple sensors (capacitive sensors for glue, distance sensors for labels) and provides unified monitoring for all consumables, reducing overall system complexity while improving reliability.
Solution Approach 2:
The system implements continuous feedback by repeatedly measuring fill levels, calculating consumption rates, and updating remaining time predictions in real-time. This feedback mechanism allows the system to adapt to changing consumption patterns and provide accurate predictions, ensuring production continuity without requiring overly complex manual monitoring procedures.
2Measurement precision
If manual checking of glue reservoirs is performed, then personnel requirements increase, but measurement precision is sufficient
Solution Approach 1:
The monitoring system performs self-service by automatically detecting fill levels using capacitive sensors for glue and distance sensors for labels. The system calculates consumption rates and predicts remaining times without human intervention, eliminating the need for manual checking while maintaining high measurement precision through electronic sensing technologies.
Solution Approach 2:
The patent replaces manual mechanical checking with electronic sensing systems. Capacitive sensors detect glue fill levels through non-contact measurement, and distance sensors similarly monitor label rolls. This substitution eliminates personnel requirements while providing precise, continuous measurement data for production planning.
3Loss of time
If threshold-based monitoring is used, then reaction time is insufficient, but device complexity is low
Solution Approach 1:
The system performs preliminary action by continuously calculating remaining consumable times based on current fill levels and consumption rates. Instead of waiting for threshold breaches, the system predicts future depletion times in advance, allowing operators to plan replenishment activities proactively and avoid production interruptions.
Solution Approach 2:
The monitoring system transitions from static threshold-based monitoring to dynamic prediction. It continuously updates consumption rates based on actual usage patterns and recalculates remaining times in real-time. This dynamic approach adapts to varying production speeds and consumption rates, providing accurate predictions without requiring complex manual calculations or overly sophisticated systems.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach allows for efficient personnel allocation and continuous production planning by predicting when consumables need replenishment, reducing production interruptions and personnel requirements by providing timely and accurate warnings based on real-time data.
Implementation Method 1
the fill level of the glue (hot glue) is preferably measured continuously by means of a capacitive sensor in a glue tank which holds the glue in molten form
Implementation Method 2
it is possible to continuously measure the fill level of the glue (cold glue), in a glue container that is inserted into the glue reservoir unit for drawing off glue continuously, measuring in a continuous and contactless manner by means of a distance sensor
Data Source
AI summary
A method for the production monitoring of a labeling machine, and a labeling machine for labeling containers, comprising a transport means for continuously supplying the containers, at least one labeling assembly for transferring labels to the containers, and at least one glue reservoir unit for continuously supplying glue for fastening the labels to the containers, is described. Accordingly, the filling state of the glue reservoir unit and a machine performance of the transport means and/or of the labeling assembly are continuously measured and, on this basis, at least one remaining running time is calculated, which indicates how long labeling can still be carried out, at the filling state, in the case of an assumed further course of machine performance. The output of the remaining running time facilitates continuous production planning and enables efficient personnel use for the required replenishment of consumables.