PACKAGING SYSTEM AND METHOD WITH FAULT ANALYSIS

Abstract

In a packaging system including a packaging machine and at least one component provided in addition to the packaging machine, the packaging system includes a display and a computer unit. The system is configured to display a performance graphic on the display. The computer unit includes a fault analysis section that is configured to detect a stop or output deficit of the packaging system and, when a stop or an output deficit is detected, to determine, from a list of error sources stored in a memory, an error source causing the stop or output deficit so that the determined error source is shown on the display.

Claims

1. A packaging system comprising a packaging machine, a display, and a computer unit, wherein the packaging system is configured to display a performance graphic on the display; the computer unit comprises a fault analysis section configured to detect a stop or an output deficit of the packaging system and, when a stop or an output deficit is detected, to determine, from an error source list stored in a memory, an error source being the cause of the stop or the output deficit; and the packaging system is further configured to indicate the determined error source on the display.

2. The packaging system according to claim 1, wherein the fault analysis section is configured to store a time stamp in association with a detected stop or a detected output deficit of the packaging system.

3. The packaging system according to claim 1, wherein the performance graphic comprises a representation of an output of the packaging system or the packaging machine over a time axis.

4. The packaging system according to claim 1, wherein at least one sensor is connected to the computer unit.

5. The packaging system according to claim 1, wherein the packaging system is configured to display fault messages and/or warnings on the display.

6. The packaging system according to claim 1, wherein the display is arranged on or in the packaging machine.

7. A method for operating a packaging system comprising a packaging machine, a display, and a computer unit including a fault analysis section, the method comprising: displaying a performance graphic on the display; storing an error source list in a memory; in the event of a stop or an output deficit of the packaging system, the fault analysis section identifying from the error source list an error source causing the stop or output deficit; and indicating the determined error source on the display.

8. The method according to claim 7, wherein the error source list is editable.

9. The method according to claim 7, wherein the performance graphic comprises a representation of an output of the packaging system or the packaging machine over a time axis.

10. The method according to claim 7, wherein the performance graphic is updated in at least one of a continuous manner and a cyclical manner.

11. The method according to claim 7, wherein at least one of recipe changes and parameter changes are displayed in or together with the performance graphic.

12. The method according to claim 7 further comprising recording and storing at least one of (i) a time of occurrence of one of a stop and an output deficit, and (ii) one of a period and a duration of one of a stop and an output deficit.

13. A fault identification system for a packaging system comprising a packaging machine, the fault identification system comprising: a computer unit configured to detect a stop or an output deficit of the packaging system and, when a stop or an output deficit is detected, to determine, from an error source list stored in a memory, an error source being the cause of the stop or the output deficit; and a display configured to display a performance graphic associated with the packaging system; wherein the computer unit is further configured to indicate the determined error source on the display.

14. The fault identification system according to claim 13, wherein the computer unit is configured to store a time stamp in association with a detected stop or a detected output deficit of the packaging system.

15. The fault identification system according to claim 13, wherein the performance graphic comprises a representation of an output of the packaging system or the packaging machine over a time axis.

16. The fault identification system according to claim 13, wherein at least one sensor is connected to the computer unit.

17. The fault identification system according to claim 13, wherein the computer unit is configured to indicate a fault message and/or warning on the display.

18. The fault identification system according to claim 13, wherein the packaging system further comprises an additional component, and wherein the additional component comprises a conveyor belt, a filler, or an inspection device.

19. The packaging system according to claim 1, wherein the packaging system comprises an additional component, and wherein the additional component comprises a conveyor belt, a filler, or an inspection device.

20. The method according to claim 7, wherein the packaging system comprises an additional component, and wherein the additional component comprises a conveyor belt, a filler, or an inspection device.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0031] In the following, advantageous embodiments of the disclosure are explained in more detail with reference to a drawing. In particular in the figures:

[0032] FIG. 1 shows an embodiment of a packaging system with a tray sealing machine;

[0033] FIG. 2 shows a second embodiment of a packaging system with a thermoforming packaging machine;

[0034] FIG. 3 shows a schematic representation of the packaging line; and

[0035] FIG. 4 shows an embodiment of a performance graphic.

[0036] Throughout the figures identical components are indicated with the same or corresponding reference signs.

DETAILED DESCRIPTION

[0037] FIG. 1 shows a first embodiment of a packaging system 1. The packaging system 1 includes a packaging machine 2, which in the present embodiment is a tray sealing machine (tray sealer). The packaging machine 2 includes a frame 3 that may support a supply roll 4 of a lidding foil 5. The packaging machine 1 further includes a feed belt 7, by means of which filled but at this point still unsealed trays 8 may be fed to a sealing station 9 of the packaging machine 2. The trays 8 may be transferred to the sealing station 9 by means of a gripper device 10 in a production direction P and may be sealed there with the lidding foil 5 (foil) supplied from above, for example by sealing the lidding foil 5 to the trays 8. For this purpose, the sealing station 9 may include a sealing tool 11. The sealed and thus completed packages may be transferred from the sealing station 9 to a discharge conveyor 12 via the gripper device 10.

[0038] In addition to the packaging machine 2, the packaging system 1 has one or more further components, in the present example a conveyor belt 13, a filler 14 and an inspection device 15. The conveyor belt 13 is used for conveying unsealed trays 8 during them being filled with a product Q. The conveyor belt 13 is used for conveying unsealed trays 8 during them being filled. A filler 14 in the vicinity of the conveyor belt 13 serves to pick up the products Q and transfer them into the trays 8. For this purpose, the filling device 14 may be configured, for example, as a suction gripper, as a transfer robot or as a (possibly intermittently operating) pouring device. Downstream of the sealing station 9 in the transport direction P there is arranged an inspection device 15, for example a vision system, a metal detector or a check weigher. The inspection device 15 is used to determine properties of the finished packages or the products packaged therein.

[0039] A display 27 is arranged on the packaging machine 2. The display has operating elements 28.

[0040] FIG. 2 shows a second embodiment of a packaging system 1, this time with a packaging machine 2 in the form of a thermoforming packaging machine. The thermoform packaging machine 2 has a forming station 16, a sealing station 17, a cross-cutting device in the form of a foil die-cutter 18 and a longitudinal cutting device 19, which are arranged in this order in a production direction P on a machine frame 20. On the input side, a feed roller 21 is located on the machine frame 20, from which a foil web 22 is drawn off. In the area of the sealing station 17, a web accumulator 23 is provided, from which a lidding foil 5 is drawn off. On the output side, a discharge device 24 in the form of a conveyor belt is provided on the thermoforming packaging machine 2, with which finished separated packages 25 are transported away. Furthermore, the thermoforming packaging machine 2 has a feed device, which grips the foil web 22 and transports it further in the production direction P per main working cycle. The feed device may be designed, for example, by means of clamp chains arranged on both sides.

[0041] In the embodiment shown, the forming station 16 is designed as a deep-drawing station, in which troughs 26 are formed in the foil web 22 by deep-drawing. The forming station 16 may be designed in such a way that several troughs 26 are formed next to each other in the direction perpendicular to the production direction P. The troughs 26 are formed by deep-drawing. An insertion section E is provided downstream of the forming station 16 in the production direction P, in which the troughs 26 formed in the foil web 16 are filled with products Q by means of a filler 14 provided in addition to the packaging machine 2.

[0042] The cross-cutting device 18 is designed as a foil die-cutter, which cuts through the foil web 22 and the lidding foil 5 in a direction transverse to the production direction P between adjacent troughs 26. The foil die-cutter 18 operates in such a way that the foil web 22 is not cut across its entire width, but is not cut through at least in an edge region. This enables controlled further transport through the feed device.

[0043] In the embodiment shown, the longitudinal cutting device 19 is designed as a knife arrangement with a plurality of rotating circular knives, with which the foil web 22 and the lidding foil 5 are cut through between adjacent troughs 26 and at the lateral edge of the foil web 22, so that separated packages 25 are present downstream of the longitudinal cutting device 19.

[0044] The thermoforming packaging machine 2 further includes a control unit 260, which has the task of controlling and monitoring the processes taking place in the thermoforming packaging machine 2. A display 27 arranged here on the thermoforming packaging machine 2 with operating elements 28 serves to visualize for or manipulate by an operator the process sequences in the thermoforming packaging machine 2.

[0045] In addition to the packaging machine 2, the packaging system 1 may also include an inspection device 15 in addition to the filler, and optionally other additional components.

[0046] FIG. 3 again schematically shows the packaging system 1 with the packaging machine 2 and components 13, 14, 15 provided in addition to the packaging machine 2. It is indicated in a schematic manner that a sensor 29 is provided on or in the packaging machine 2 as well as on or in the conveyor belt 13 in each case, by means of which at least one parameter of the associated machine 2 or component is monitored.

[0047] The packaging machine 2 as well as the additional components 13, 14, 15 and the sensors 29 are connected to a computer unit 31 via data and control lines 30. The computer unit may be a control computer for the packaging system 1. The computer unit has a fault analysis section 32 and a memory 33 that stores an error source list 34. The error source list 34, also shown in an enlargement, may include a number of different faults F1, F2, F3, . . . , each fault F1, F2, F3 being associated with a particular or a most probable error source f1, f2, f3, It is quite conceivable that different faults F1, F2, F4 are assigned to the same error source f1. An error source f1, f2, f3 may be a specific component 2, 13, 14, 15 of the packaging system 1 or it may be a specific fault within such a component.

[0048] A performance graphic 35, which is shown in enlarged form in FIG. 4, may be displayed on the display 27 of the packaging system 1 connected to the computer unit 31. The performance graphic 35 represents an output of the packaging system 1 over a certain period of time, specifically as an output L (packages per unit time) over a time axis t. As explained at the outset, the packaging system 1 has a rated output LN that it may or should achieve during trouble-free normal operation. Depending on various factors, the actual output L(t) achieved may fluctuate, as shown in FIG. 4.

[0049] An output L below a certain output threshold LS is taken to be an output deficit. The fault analysis section 32 of the packaging system 1 is designed to detect when an output deficit occurs.

[0050] In the example according to FIG. 4, the packaging system 1 starts at its nominal output at time t0. At time t1, the output L falls below the output threshold LS for the first time. Up to time t2, there is an output deficit of the packaging system 1, and only then does the output L rise above the output threshold LS again.

[0051] At time t3, the output of the packaging system 1 again falls below the output threshold LS until a complete stop at time t4. Only at time t5 does the packaging system 1 operate again at its rated output LN. At time t6 an abrupt stop occurs, i.e., the output L is reduced to zero. At time t7, the packaging system 1 starts to operate again; at time t8, the output threshold LS is exceeded.

[0052] An output deficit, i.e., an output L below the threshold LS, thus occurs between the times t1 and t2, between the times t3 and t5, and between the times t6 and t8. A stop of the packaging system 1 occurs between times t4 and t5, and between times t6 and t7.

[0053] As soon as the fault analysis section 32 has identified a (most probable) reason for the occurrence of a particular stop or output deficit, i.e., the error source f1, f2, f3 causing it, the identified error source f1, f2, f3 is indicated on the display 27, preferably within the performance graphic 35. FIG. 4 shows an example of how this may be accomplished. Each time of the occurrence of an output deficit or a stop t1, t3, t4 is associated with a display of the error source f1, f2, f3 recognized as causal therefor, as indicated in FIG. 4. For clarity, a determined error source for the occurrence of the stop at time t6 has been omitted. Within the memory 33, each stop or output deficit determined by the fault analysis section 32 may be stored together with an associated timestamp t1, t3, t4, t6. Additionally or alternatively, it is possible to record and store the time duration of each stop or output deficit.

[0054] It is noted that the machine 2, conveyor belt 13, filler 14, inspection device 15, display 27, sensors 29, computer unit 31, including fault analysis section 32, control unit 260, and/or any other computer, system, unit, controller, machine, terminal, device, module, arrangement, feature, element, function, functionality, step, algorithm, operation, or the like described herein may comprise and/or be implemented in or by one or more appropriately programmed processors (e.g., one or more microprocessors including central processing units (CPU)) and associated memory (e.g., memory 33) and/or storage, which may include data, firmware, operating system software, application software and/or any other suitable program, code or instructions executable by the processor(s) for controlling operation thereof and/or for performing the particular algorithms represented by the various functions and/or operations described herein, including interaction between, control of, and/or cooperation with each other or any other components, machines, or devices. One or more of such processors, as well as other circuitry and/or hardware, may be included in a single ASIC (Application-Specific Integrated Circuitry) or individually packaged or assembled into a SoC (System-on-a-Chip). As well, several processors and various circuitry and/or hardware may be distributed among several separate components, machines, devices, and/or locations, such as a mobile unit, mobile computing device, mobile terminal, or a remote server.

[0055] The packaging system according to the disclosure or the process according to the disclosure may be modified in many ways. It is conceivable that the performance graphic could be updated continuously or on a cycle-by-cycle basis. It is possible for the operator to use a zoom function to enlarge presentation of certain periods of time, or to display larger periods of time, i.e., to change the scale of the time axis t. There is also the possibility for a statistical evaluation of the determined faults and error sources as well as for an editing of the error source list 34, for example via the display 27 or from external devices.