Packaging Machine Early Start Using Predicted Process End Timing
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Solution Overview
Problem
Existing packaging machines require complex and time-consuming setup of process times by operators, leading to delays and reduced performance, especially when switching between different product batches or tool changes, due to rigid time-controlled operations.
Innovation Solution
A packaging machine with a control unit connected to measuring devices that detects actual process values and adjusts program sequences in a self-controlling manner, allowing for early starts based on measured variables and reaction times, enabling flexible operation and adaptation to current production conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If time-controlled operations are used with preset process times, then the packaging machine can operate with a fixed schedule, but the setup time increases and performance decreases when switching between product batches
Solution Approach 1:
The patent transitions from static time-controlled operations to dynamic process-controlled operations. The control unit continuously monitors actual process values from measuring devices and automatically adjusts the timing of individual processes in real-time, allowing the system to adapt dynamically to different product batches and tool changes without requiring manual reconfiguration of preset times.
Solution Approach 2:
The packaging machine performs self-adjustment through automatic recognition of tool characteristics and product parameters. The control unit uses measuring devices to detect actual process values and autonomously optimizes process timing, eliminating the need for operator intervention during batch changes and reducing setup time while maintaining high productivity.
2Adaptability or versatility
If preset process times are adjusted manually by operators, then the packaging machine can be adapted to different products, but the complexity of setup increases and requires profound knowledge
Solution Approach 1:
The patent implements a feedback control system where measuring devices continuously monitor actual process values (such as temperature, pressure, position) and feed this information back to the control unit. The control unit compares actual values with target values and automatically adjusts process timing and parameters, enabling easy adaptation to different products without requiring operators to manually complex adjustments.
Solution Approach 2:
The patent replaces manual operator adjustment with automated electronic control. Instead of operators manually setting process times based on experience and knowledge, the control unit automatically determines optimal timing based on measured process values, substituting human expertise with an automated intelligent system that reduces setup complexity.
3Productivity
If rigid time control is used for early start functions, then the operation schedule is simple, but delays occur when process times change leading to reduced performance
Solution Approach 1:
The patent dynamically changes process parameters (timing, temperature, pressure) based on actual measured values rather than using fixed preset values. The control unit continuously monitors process state and adjusts the early start timing of subsequent processes based on the actual completion status of preceding processes, ensuring reliable operation even when process conditions vary between batches.
Data Source
AI summary
A packaging machine, comprising a control unit, a plurality of measuring devices and a plurality of working units for different processes. The control unit is functionally connected to the working units and the measuring devices. A work cycle at the packaging machine comprises at least a first functional process and a second functional process at one or at different working units, the second functional process starting later than the first functional process. The control unit may execute an early start for the second functional process of a working unit, when an actual process value of the preceding first functional process of the program sequence of one of the working units has not yet reached the respective target process value. The control unit may control the early start of the second functional process based on an approximation method for predetermining the temporal end of the first functional process.