Packaging machine having a process-controlled early start function

Patent metadata

Field	Value
Publication number	US-11021288-B2
Application number	US-201615750488-A
Country	US
Kind code	B2
Filing date	Aug 8, 2016
Priority date	Aug 6, 2015
Publication date	Jun 1, 2021
Grant date	Jun 1, 2021

Abstract

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.

First claim

The invention claimed is:

1. A packaging machine comprising: a control unit, a plurality of measuring devices, and a plurality of working units for different processes, wherein the control unit is functionally connected to the working units and the measuring devices,
wherein the plurality of measuring devices are configured to detect one or more actual process values at the plurality of working units and forward the one or more actual process values to the control unit, so as to monitor a process status at one or more of the plurality of working units;
wherein the control unit is configured to establish in a self-controlling manner, by a comparison of the one or more actual process values forwarded to the control unit from the plurality of measuring devices and of associated target process values from one of a memory connected to the control unit, a program sequence for the respective individual working units or an adaptation of the program sequences of one or more of the plurality of working units, wherein each of the one or more of the plurality of working units is operable according to its own program sequence established or adapted depending on the actual process values detected thereat;
wherein a work cycle at the packaging machine comprises at least a first functional process and a second functional process at one or at different of the plurality of working units, the second functional process being startable later than the first functional process;
wherein the control unit is configured for executing 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 the working unit or of another working unit has not yet reached the respective target process value;
wherein the control unit is configured for executing the early start based on a predetermined reaction time of the working unit for the second functional process of the program sequence of the working unit; and
wherein the control unit is configured for controlling the early start of the second functional process based on an approximation method for predetermining the temporal end of the first functional process using a time-dependent measured variable of the first functional process detected at the working unit using one of the plurality of measuring devices.

2. The packaging machine according to claim 1 , wherein the control unit is configured to determine, based on the approximation method, a residual remaining time of the preceding first functional process, said remaining time indicating the length of time until the measured variable will reach the target process value, the control unit being additionally configured for executing the early start, when the remaining time is shorter than or equal to the predetermined reaction time.

3. The packaging machine according to claim 1 , wherein using the approximation method, a process-dependent rate of change of a time-dependent measured variable of the first functional process is determinable, the measured variable being detectable at the working unit using one of the measuring devices, or an adaptation to a predetermined mathematical function is executable.

4. The packaging machine according to claim 3 , wherein a threshold value for the rate of change is stored for the control unit, wherein the control unit is configured to start a calculation of the remaining time, when the rate of change corresponds to the threshold value or is smaller than the threshold value.

5. The packaging machine according to claim 4 , wherein the control unit is configured for determining the threshold value on the basis of a trend control.

6. The packaging machine according to claim 5 , wherein the control unit is configured to increase or decrease the threshold value step by step until the calculated remaining time is, at least once, longer than the predetermined reaction time.

7. The packaging machine according to claim 6 , wherein the control unit is connected to a circular buffer for specifying the condition.

8. The packaging machine according to claim 2 , wherein the control unit is configured to continuously execute a calculation of the remaining time and to delay the early start until the calculated remaining time is shorter than or equal to the predetermined reaction time.

9. The packaging machine according to claim 3 , wherein the measured variable is a pressure, which is applied to the working unit and which is detectable using a pressure sensor formed on the working unit and functionally connected to the control unit, and that the rate of change calculable using the control unit-determines a variation rate of the detected pressure.

10. The packaging machine according to claim 1 , wherein the control unit is configured to determine a reaction time based on a time measurement, wherein the reaction time is specified as the length of time between an activation of a start signal and an adjusting movement thus caused at the drive unit or has already been specified on the basis of a change of a pressure applied to the working unit or a rate of change of the pressure.

11. The packaging machine according to claim 1 , wherein the control unit is configured to cyclically determine a reaction time in the case of each functional process, and to calculate an averaged reaction time by averaging a predetermined number of said determined reaction times, the early start of the second functional process being executable with respect to said averaged reaction time.

12. The packaging machine according to claim 11 , wherein the control unit comprises an emergency control for operating the packaging machine, the control unit being configured to replace the process-data-based control of the packaging machine by a time-based control, when a predetermined number of said calculated average reaction times reaches or exceeds a functional threshold value during the operation of the packaging machine.

13. The packaging machine according to claim 1 , wherein the packaging machine is a thermoform packaging machine, a tray sealer or a belted chamber machine.

14. The packaging machine according to claim 1 , wherein the target process values indicate one of an optimum molding and/or sealing temperature, an optimum heating, sealing or molding pressure, or for a working unit configured as a molding station at least one stabilization time.

15. The packaging machine according to claim 1 , wherein the respective measuring devices comprise at least one force, pressure, position, temperature, infrared, ultrasonic, induction, laser and/or moisture sensor.

16. A method of self-controlling a program sequence of a process at at a plurality of working units of a packaging machine comprising the steps of:
executing at one or more working units the program sequence of one process or the program sequence of a plurality of processes that are functionally adapted to one another while the packaging machine is in operation;
detecting actual process values at the one or more of the plurality of working units;
forwarding the detected actual process values to a control unit of the packaging machine;
comparing the actual process values forwarded to the control unit with associated target process values; and
establishing, in a self-controlling manner, the respective program sequence for the individual working units and/or adapting the respective program sequences of the respective working units with respect to one another; and
coordinating the operation of the packaging machine based upon the established and/or adapted program sequences, wherein within a work cyc

Assignees

• Multivac Haggenmueller Kg

Inventors

• Enderle Tobias
• Holderied Thomas
• Botzenhardt Claus

Classifications

• G05B19/0426

  Programming the control sequence · CPC title

• B65B47/02

  with means for heating the material prior to forming · CPC title

• B65B57/00 Primary

  Automatic control, checking, warning, or safety devices (registering wrapping or container-forming material fed from rolls B65B41/18) · CPC title

• B29C66/112

  Single lapped joints · CPC title

• B65B51/14

  by reciprocating or oscillating members (B65B51/148 takes precedence) · CPC title