Packaging Machine Consumable Usage Monitoring System
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Solution Overview
Problem
There is a need for an improved system and method to monitor the use of consumable materials in packaging machines that operate in different modes, as existing systems cannot easily determine the usage rates or modes of operation, especially in remote locations where data collection is challenging.
Innovation Solution
A system and method that includes packaging machines with controllers and communication ports to collect consumable usage data, a portable module for electronic connection to machines to receive and store this data, and a user interface to provide indications of usage in different modes, allowing for centralized data compilation and reporting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a single packaging machine operates in multiple modes using the same consumable materials, then the machine's versatility and adaptability are improved, but the ability to determine usage rates and modes of operation deteriorates
Solution Approach 1:
The system implements feedback by having the controller continuously monitor and record consumable usage data, then provide this information through a user interface. This feedback loop allows operators to see real-time or historical usage patterns, enabling them to determine which modes are being used and at what rates, even when the same materials are consumed across multiple operating modes.
Solution Approach 2:
The controller acts as an intermediary between the packaging machine's multiple operating modes and the user interface. It collects raw consumable usage data from various modes, processes this information, and presents it in a meaningful format through the display. This intermediary function resolves the information loss by translating complex multi-mode usage data into clear, actionable insights.
2Ease of operation
If packaging machines are operated in remote locations, then operational flexibility is improved, but the ease of data collection deteriorates
Solution Approach 1:
The packaging machine performs self-service regarding data collection by automatically monitoring and recording its own consumable usage through an integrated controller. This eliminates the need for external manual data collection, allowing machines to be operated in remote locations without compromising data accessibility. The system serves itself by generating, storing, and making available its own operational data.
Solution Approach 2:
The system replaces manual data collection methods with electronic automated monitoring. Instead of physically tracking consumable usage or manually recording operational data, the controller electronically captures and stores usage information, which can then be retrieved through the user interface. This substitution of mechanical/manual processes with electronic automation enables effective data collection even in remote operating locations.
3Measurement precision
If consumable usage data is collected and stored electronically, then measurement precision is improved, but the device complexity increases
Solution Approach 1:
The controller serves multiple functions: it controls the packaging machine's operation, monitors consumable usage, stores data, and provides information through the user interface. By consolidating these diverse functions into a single multi-functional device, the system achieves precise electronic data collection without proportionally increasing overall complexity. The universal controller handles all data-related tasks, eliminating the need for separate specialized components.
Data Source
AI summary
A system and method for monitoring the use of consumable materials in packaging machines is provided. The system generally includes a plurality of packaging machines that are configured to selectively operate in first and second modes to perform different packaging operations, e.g., by using consumable materials at different consumable usage rates to form different packaging devices. A controller in each machine controls the operation of the machine in the different modes and is configured to communicate the consumable usage data via a port. A portable module can be electronically connected to each machine during a connection session to communicate with the controller and receive the consumable usage data. The data from the module is then received by a user interface that provides an indication to a user of the usage of the machines in the first and second modes, e.g., to indicate to the user which machines are being used to form which packaging devices and/or how much of the operation of the machines is being used to form each of the packaging devices.