Receptacle Handling Wear Prediction From Process Quality Classes
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
In the beverage bottling industry, existing maintenance methods require expert knowledge and lead to unplanned stoppages and increased resource expenditure due to reactive maintenance, as operators must manually analyze complex sensor data for troubleshooting and component wear prediction.
Innovation Solution
A predictive maintenance apparatus that receives and analyzes process data from receptacle handling installations to classify handling operations, derive component wear states, and provide action recommendations, using an electronic computing device that can be centralized or decentralized, and communicates with installation controls to support proactive maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual analysis of sensor data is performed by operators, then troubleshooting capability is achieved, but expert knowledge is required and unplanned stoppages occur
Solution Approach 1:
The system enables self-service maintenance through automated analysis of sensor data by the control device, which independently identifies component wear states and generates maintenance recommendations without requiring operator intervention or expert knowledge
Solution Approach 2:
The patent replaces manual mechanical analysis by operators with an automated electronic system that processes sensor data using algorithms to determine wear states, substituting human expertise with computational analysis
2Reliability
If reactive maintenance is performed based on manual analysis, then faults are addressed, but unplanned stoppages and increased resource expenditure occur
Solution Approach 1:
The system performs preliminary maintenance actions by continuously monitoring sensor data and predicting component wear states before actual failures occur, enabling planned maintenance interventions that prevent unplanned stoppages
Solution Approach 2:
The control device establishes a feedback loop by continuously analyzing sensor data from the receptacle handling installation, comparing it against reference values, and generating maintenance recommendations based on detected deviations that indicate component wear
3Reliability
If preventive maintenance replaces flawless components, then system reliability is maintained, but resource expenditure increases
Solution Approach 1:
The system changes the maintenance approach from time-based or usage-based replacement to condition-based maintenance by analyzing sensor data parameters to determine actual component wear states, replacing components only when wear exceeds defined thresholds
Data Source
AI summary
An apparatus, system and method for predictively maintaining a receptacle handling installation, for example a beverage bottling installation, wherein the apparatus is configured to receive process data of at least one handling operation on one or more receptacles, performed by the receptacle handling installation; assign the handling operation to at least one of multiple quality classes on the basis of the process data; and derive a state of wear for one or more components of the receptacle handling installation from an analysis of the quality classes.