Packaging Machine Recipe Generation for Faster Changeover Setup
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Solution Overview
Problem
Packaging machines require extensive effort and expertise to set up for new products, packaging materials, or tools, often necessitating multiple test runs to find suitable machine settings, which is inefficient and can only be done by trained operators.
Innovation Solution
A packaging machine with a control unit featuring a process parameter generator and a recipe generator that uses a set of rules to determine recipe variables from various information sources, including product, packaging type, tools, and materials, to generate a recipe data record for optimal parameterization, reducing machine changeover times and simplifying the setup process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual setup process with pre-programming is used, then machine settings can be determined, but setup time and operator expertise requirements increase significantly
Solution Approach 1:
The system performs preliminary determination of process parameters using a rule generator before actual production. The rule generator creates initial parameter settings based on recipe data and product information, preparing the machine in advance for specific products, thereby reducing setup time while maintaining reliable settings.
Solution Approach 2:
The machine system determines process parameters autonomously using the rule generator and recipe data without requiring extensive manual intervention. The system serves itself by automatically generating and adjusting parameters based on pre-stored rules and product information, reducing dependency on operator expertise and time investment.
2Manufacturing precision
If multiple test runs are performed to optimize parameters, then optimal process parameters are achieved, but productivity decreases due to repeated adjustments
Solution Approach 1:
Optimal process parameters are determined in advance through the rule generator using recipe data and product information before actual production begins. This preliminary optimization eliminates the need for multiple test runs during production, achieving both parameter optimization and maintained productivity.
Solution Approach 2:
The system uses feedback from measured values during operation to adjust and optimize parameters. The control unit receives measured values from the manufacturing process and uses them to refine parameter settings, achieving optimal parameters through controlled feedback rather than repeated test runs.
3Adaptability or versatility
If complex pre-programming is required for setup, then complete machine configuration is achieved, but device complexity and operator training requirements increase
Solution Approach 1:
The system extracts and separates the parameter determination logic into a rule generator that operates independently from the main control unit. The rule generator contains pre-stored rules for parameter determination, extracting complexity from the setup process and making it modular, thereby reducing overall system complexity while maintaining configuration capability.
Solution Approach 2:
Recipe data and parameter rules are pre-programmed and stored in the system before operation. This preliminary preparation of configuration data and rules allows the machine to be easily configured for different products without requiring complex on-site programming, reducing setup complexity while maintaining adaptability.
Data Source
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AI summary
The invention relates to an apparatus (V), comprising a packaging machine (100), which comprises a control unit (1) having a process parameter generator (PG) designed to determine specific process parameters (P) for a production process (H) of the packaging machine (100). The control unit (1) of the packaging machine (100) also comprises a recipe generator (RG) for an adjustment process (E) of the packaging machine (100) preceding the production process (H) or can be connected to a recipe generator (RG') of the apparatus, which generator is designed as a separate unit. The respective recipe generator (RG, RG') comprises a set of rules (RW) for determining recipe variables (RV) for the adjustment process (E) of the packaging machine (100) and is designed to generate the recipe variables (RV) with reference to a plurality of data (I) and to form therefrom a recipe data set (RD) for the adjustment process (E) of the packaging machine (100). The invention further relates to a method therefor.