Packaging Machine Recipe Control for Faster Changeovers
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Solution Overview
Problem
Packaging machines require significant effort and expertise to adjust for new products, materials, or tools, often necessitating multiple test runs to determine optimal process parameters, making it difficult for operators to initiate reliable production.
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 specific process parameters based on product, packaging type, tool, and film data, facilitating the creation of a recipe data set for optimal machine adjustment, reducing changeover times and simplifying the adjustment process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual adjustment process is used with multiple test runs, then optimal process parameters can be determined, but adjustment time and complexity increase significantly
Solution Approach 1:
The system performs preliminary actions by pre-programming optimal process parameters into a database before actual production. When a product is to be packaged, the corresponding pre-programmed parameters are automatically retrieved and applied, eliminating the need for manual trial-and-adjustment processes during actual production setup.
Solution Approach 2:
The system creates digital copies of optimal process parameters for different products, packaging materials, and tools in a database. These parameter copies can be automatically retrieved and applied when needed, replacing manual parameter determination through test runs.
2Reliability
If skilled machine adjusters perform manual adjustment, then reliable process parameters are achieved, but operator expertise requirement increases
Solution Approach 1:
The system performs self-service by automatically selecting and applying the appropriate pre-programmed process parameters based on the product, packaging material, and tool being used. The control unit autonomously retrieves parameters from the database and configures the packaging machine without requiring skilled operators to manually adjust settings.
Solution Approach 2:
The system replaces the mechanical/manual adjustment process with an automated control system. The control unit electronically retrieves and applies process parameters from the database, substituting the manual mechanical adjustment that previously required skilled operators.
3Reliability
If multiple test runs are conducted to determine optimal parameters, then production reliability improves, but productivity during changeover decreases
Solution Approach 1:
Optimal process parameters are determined and pre-programmed into the database in advance during the preliminary development phase. This eliminates the need for time-consuming test runs during actual production changeovers, as the parameters are already optimized and ready for immediate application.
Solution Approach 2:
The system uses pre-created parameter copies for different products and materials stored in the database. During changeover, the appropriate parameter copy is automatically retrieved and applied, enabling rapid switching between different production configurations without repeating test runs.
Data Source
AI summary
An apparatus comprising a packaging machine, which comprises a control unit having a process parameter generator designed to determine specific process parameters for a production process of the packaging machine. The control unit of the packaging machine also comprises a recipe generator for an adjustment process of the packaging machine preceding the production process or can be connected to a recipe generator of the apparatus, which generator is designed as a separate unit. The respective recipe generator comprises a set of rules for determining recipe variables for the adjustment process of the packaging machine and is designed to generate the recipe variables with reference to a plurality of data and to form therefrom a recipe data set for the adjustment process of the packaging machine. A method for using the apparatus is also included.