A SYSTEM AND METHOD FOR CONTROLLING A MANUFACTURING PROCESS FOR PACKAGING UNITS
20220144471 · 2022-05-12
Inventors
- Paolo Scarabelli (Reggio Emilia, IT)
- Antonio Marsella (Bologna, IT)
- Lorenzo Tacconi (Modena, IT)
- Antonio Melandri (Rubiera, IT)
- Marco Melandri (Bologna, IT)
- Matteo Gazzadi Poggioli (Modena, IT)
- Stefano Vicini (Vignola, IT)
- Claudio Donati (Modena, IT)
- Mattia Verasani (San Martiono in Rio, IT)
Cpc classification
G05B2219/31424
PHYSICS
B65B41/18
PERFORMING OPERATIONS; TRANSPORTING
Y02P90/80
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
B65B59/00
PERFORMING OPERATIONS; TRANSPORTING
B65B61/025
PERFORMING OPERATIONS; TRANSPORTING
B65B57/00
PERFORMING OPERATIONS; TRANSPORTING
B65B9/08
PERFORMING OPERATIONS; TRANSPORTING
B65B57/02
PERFORMING OPERATIONS; TRANSPORTING
G05B19/4183
PHYSICS
International classification
B65B57/02
PERFORMING OPERATIONS; TRANSPORTING
B65B41/18
PERFORMING OPERATIONS; TRANSPORTING
B65B9/08
PERFORMING OPERATIONS; TRANSPORTING
Abstract
A system (200) for controlling a manufacturing process for packaging units (301′, 302′) is disclosed, the packaging units are manufactured from a packaging material (301, 302) comprising machine readable identifiers (c1, c2). A control unit (210) associates the identifiers with corresponding data images (201, 202) of the packaging units, wherein for a first process application (a1) to manipulate packaging material (301) based on a first set of process parameters (p1), the control unit is configured to store at least part of the first set of process parameters (p1) to the associated data image, wherein for a subsequent second process application (a2) to manipulate said packaging material (301), read at least part of the first set of process parameters (p1) stored in said associated data image (201) to control the second process application (a2) based on at least part of the first set of process parameters (p1).
Claims
1. A method of controlling a manufacturing process for packaging units for food, the method comprising, by a processor: providing machine readable identifiers on a packaging material for the packaging units, associating the identifiers with corresponding data images of the packaging units, whereby for a series of packaging units, to be manufactured from a corresponding series of packaging material, each packaging unit in the series has a corresponding data image being identifiable by an associated identifier on the packaging material thereof, for a first process application to manipulate a packaging material from which a first packaging unit is manufactured based on a first set of process parameters: registering a first identifier on said packaging material to be manipulated to identify the associated data image, and storing at least part of the first set of process parameters to the associated data image, and for a subsequent second process application to manipulate said packaging material from which the first packaging unit is manufactured: registering the first identifier to identify the associated data image, and reading at least part of the first set of process parameters stored in said associated data image to control the second process application based on at least part of the first set of process parameters.
2. The method according to claim 1, further comprising: for a plurality of process applications to manipulate said packaging material from which the first packaging unit is manufactured: storing at least part of an associated plurality of process parameters to the data image of the first packaging unit, and controlling subsequent process applications, downstream of said plurality of process applications, based on at least part of the plurality of process parameters stored in the data image of the first packaging unit.
3. The method according to claim 2, further comprising: creating a virtual packaging unit entity based on at least part of said plurality of process parameters to be accessed by a user for subsequent evaluation of the manufacturing process.
4. The method according to claim 1, further comprising: controlling the second process application for a series of packaging units based on at least part of first sets of process parameters stored, from the first process application, in associated data images of the series of packaging units.
5. The method according to claim 1, further comprising: monitoring the data images for deviations from pre-determined criteria comprising said first set of process parameters.
6. The method according to claim 5, further comprising: communicating control instructions to the second process application comprising modified process parameters based on said deviations.
7. The method according to claim 5, further comprising: inputting the data images to an artificial intelligence application for subsequent detection of deviations in said process parameters.
8. The method according to claim 5, further comprising: analyzing said packaging units to detect categories of defects based on said deviations.
9. A system for controlling a manufacturing process for packaging units for liquid food, wherein the packaging units are manufactured from a packaging material comprising machine readable identifiers, the system comprising: a control unit configured to: associate the identifiers with corresponding data images of the packaging units, whereby for a series of packaging units, to be manufactured from a corresponding series of packaging material, each packaging unit in the series has a corresponding data image being identifiable by an associated identifier on the packaging material thereof, for a first process application to manipulate a packaging material from which a first packaging unit is manufactured based on a first set of process parameters: register a first identifier on said packaging material to be manipulated to identify the associated data image, and store at least part of the first set of process parameters to the associated data image, and for a subsequent second process application to manipulate said packaging material from which the first packaging unit is manufactured: register the first identifier to identify the associated data image, and read at least part of the first set of process parameters stored in said associated data image to control the second process application based on at least part of the first set of process parameters.
10. The system according to claim 9, wherein the control unit comprises: a communication interface configured to communicate with the first and second process applications and to receive identifier data comprising said identifier, a processor connected to the communication interface and configured to associate the identifier with said corresponding data image stored in a memory, wherein the communication interface is configured to receive said at least part of first set of process parameters from the first process application, and wherein the processor is configured to: store said at least part of first set of process parameters to the data image of an associated first packaging unit, and for the subsequent second process application, read said at least part of first set of process parameters stored in said data image and send control instructions to the second process application for manipulation of the packaging material associated with said data image based on at least part of the first set of process parameters.
11. The system according to claim 9, further comprising an image detector in communication with the control unit and being configured to register image data of the packaging material to detect the machine readable identifiers.
12. The system according claim 9, wherein the process parameters comprise at least one of mechanical characteristics, electrical characteristics, chemical characteristics, or motion profile characteristics of at least one of the packaging material, the packaging units, the first process application, the second process application, or the food to be filled in the packaging units.
13. The system according to claim 9, wherein the process parameters comprises image data of at least one of the packaging material, or of the packaging units.
14. The system according to claim 9, wherein the process parameters comprises environmental parameters of at least one of the first or second process application.
15. The system according to claim 9, wherein the machine readable identifiers comprises a data pattern comprising at least one of printed elements, embossed elements, magnetic elements or electromagnetic elements.
16. A non-transitory computer storage medium program product comprising instructions which, when executed by a computer, cause the computer to carry out the method according to claim 1.
17. A packaging machine comprising the system according to claim 9.
18. A packaging machine performing the method according to claim 1.
Description
DRAWINGS
[0012] Embodiments of the invention will now be described, by way of example, with reference to the accompanying schematic drawings.
[0013]
[0014]
[0015]
[0016]
[0017]
DETAILED DESCRIPTION
[0018] Embodiments of the invention will now be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all, embodiments of the invention are shown. The invention may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein.
[0019]
[0020] Turning again to
[0021] In one example, process parameters (p.sub.1) may be stored to a particular data image 201 in the first process application (a.sub.1) which are indicative of mechanical deviation of the associated packaging unit 301′. The aforementioned data is then accessible in a subsequent process application (p.sub.2) which may discard the particular packaging unit 301′ or adapt its control or process parameters (p.sub.2) to compensate for the deviation. E.g., the mechanical, physical, or chemical characteristics of the packaging material 301, 302, or packaging units 301′, 302′, can be taken into account for such compensation. In another example, in case any part of the manufacturing line has been temporarily interrupted, e.g. during a calibration process or a maintenance routine, any of the process parameters (p.sub.1) may have been affected. By accessing the data images 201, 202, the process applications (a.sub.2) may compensate for the affected process parameters (p.sub.1) once the production is resumed. Associating the packaging units with corresponding data images and storing process parameters to each unique data image to be subsequently utilized for controlling manipulation of each unique unit in a process application further downstream in the line hence allows for dynamically varying and optimizing the process parameters across the manufacturing line for each packaging unit taking into account each unique characteristic thereof.
[0022] The process applications (a.sub.1, a.sub.2) as discussed may relate to any part of the manufacturing chain, such as forming and preparing the packaging material for different sealing operations, as well as filling the packaging units 301′, 302′, with content and providing any additional components onto the packaging units 301′, 302′, such as caps, straws etc. Process applications (a.sub.1) which introduce the filler product also provides for updating the unique data images 201, 202, with associated process parameters (p.sub.1), such as filler product information, e.g. general data relating to the type of product, as well as dynamic individual data, e.g. temperature variations in the filling step. Related process applications (a.sub.2) can access the data images 201, 202, to optimize the application parameters (p.sub.2). E.g. air pressure inside a packaging unit 301′ can be optimized during filling of a product for a particular type of material 301 where the mechanical characteristics thereof is stored in the first set of process parameters (p.sub.1).
[0023] The principles described in relation to
[0024] The control unit 210 is configured to associate 1020 the identifiers (c′.sub.3, c′.sub.4) with corresponding data images 203, 204, of the packaging units 303′, 304′. Thus, each packaging unit 303′, 304′, has a corresponding data image 203, 204, being identifiable by an associated identifier (c′.sub.3, c′.sub.4). A first process application (A.sub.1) manipulates the packaging material 303 from which a first packaging unit 303′ is manufactured based on a first set of process parameters (P.sub.1). The control unit 210 is configured to register 1030 a first identifier (c′.sub.3) on the packaging material 303 to be manipulated to identify the associated data image 203, and store 1040 at least part of the first set of process parameters (P.sub.1) to the associated data image 203. For a subsequent second process application (A.sub.2) to manipulate said packaging material 303, the control unit 210 is configured to register 1050 the first identifier (c′.sub.3) to identify the associated data image 203, and read 1060 at least part of the first set of process parameters (P.sub.1) stored in said associated data image 203 to control 1070 the second process application (A.sub.2) based on at least part of the first set of process parameters (P.sub.1). As described in relation to
[0025]
[0026] Turning to
[0027] The system 200 may comprise an image detector 214 in communication with the control unit 210. The image detector may be configured to register image data of the packaging material 301, 302, 303, 304, to detect the machine readable identifiers (c.sub.1, c.sub.2, c′.sub.3, c′.sub.4). As schematically illustrated in
[0028] As elucidated above, the process parameters (p.sub.1, p.sub.2, p.sub.n, P.sub.1, P.sub.2, P.sub.n) may comprise mechanical characteristics, and/or electrical characteristics, and/or chemical characteristics, and/or motion profile characteristics of the packaging material 301, 302, 303, 304, and/or of the packaging units 301′, 302′, 303′, 304′, and/or of the first and/or second process application (a.sub.1, a.sub.2, A.sub.1, A.sub.2), and/or of the food to be filled in the packaging units 301′, 302′, 303′, 304′. This provides for building the data images 201, 201, 203, 204, of the packaging units 301′, 302′, 303′, 304′, with a wide range of characteristics to be evaluated and utilized when optimizing numerous aspects of the application processes.
[0029] The process parameters (p.sub.1, p.sub.2, p.sub.n, P.sub.1, P.sub.2, P.sub.n) may also comprise image data of the packaging material 301, 302, 303, 304, and/or of the packaging units 301′, 302′, 303′, 304′. The image date may be indicative of various types of deviations which can be utilized as control input to subsequent application processes to either compensate or correct for the deviations or take other actions such as discarding the affected packaging units.
[0030] The process parameters (p.sub.1, p.sub.2, p.sub.n, P.sub.1, P.sub.2, P.sub.n) may further comprise environmental parameters such as temperature, and/or humidity, of the environment of the first and/or second process application (a.sub.1, a.sub.2, A.sub.1, A.sub.2). This provides for optimizing process applications where such environmental parameters may affect the packaging material 301, 302, 303, 304.
[0031] The machine readable identifiers (c.sub.1, c.sub.2, c′.sub.3, c′.sub.4) may comprise a data pattern comprising printed elements such as data matrices and QR codes, and/or embossed elements, and/or magnetic elements and/or electromagnetic elements to be utilized in RFID communication.
[0032]
[0033] The method 1000 may comprise creating 1080 a virtual packaging unit entity 215, 216, based on at least part of the plurality of process parameters (p.sub.1, p.sub.2, P.sub.1, P.sub.2).
[0034] The packaging unit entities 215, 216, may be accessed by a user for subsequent evaluation of the manufacturing process, both in terms of optimizing the processes as described above, and from an end-consumer perspective where the consumer may access an adapted version of the virtual packaging unit 215, 216, to see a chain of e.g. food origin and transport with data such as time stamps.
[0035] The method 100 may comprise controlling 1072 the second process application (a.sub.2) for a series of packaging units 301′, 302′, based on at least part of first sets of process parameters (p.sub.1, p′.sub.1) stored, from the first process application (a.sub.1), in associated data images 201, 202, of the series of packaging units 301′, 302′. Hence, the second process application (a.sub.2) may be continuously optimized for each packaging unit 301′, 302′, being received for manipulation by the second process application (a.sub.2). The identifiers (c.sub.1, c.sub.2) may thus be registered in real-time for continuously accessing the related data images 201, 202, and the process parameters (p.sub.1, p′.sub.1) stored therein.
[0036] The method 1000 may comprise monitoring 1061 the data images 201, 202, 203, 204, for deviations from pre-determined criteria comprising the first set of process parameters (p.sub.1, P.sub.1). The pre-defined criteria may comprise defined thresholds of the process parameters (p.sub.1, P.sub.1). Different control actions may be defined depending on the detected deviations.
[0037] For example, the method 1000 may comprise communicating 1073 control instructions to the second process application (a.sub.2, A.sub.2) comprising modified process parameters based on such deviations. This provides for adjusting the second process application (a.sub.2, A.sub.2) to compensate for the deviations. This also provides for optimizing the detection of any defects. E.g. in case a deviation for a set of packaging units is detected, the set may be selected for a prioritized screening procedure to locate the origin of the deviation or defect. This allows for a facilitated quality control with optimization and prioritization for packaging units in a batch for which deviations where detected. Different categories such package integrity, package quality, and product quality may be assessed. Data from both the physical properties of the finished packaging units 301′, 302′, and the final data images 201, 202, may be evaluated for deviations. E.g. the data may contain information when the error/deviation has occurred, e.g. for which application.
[0038] The method 1000 may comprise analyzing 1063 the packaging units 301′, 302′, 303′, 304′, to detect categories of defects based on deviations as discussed above.
[0039] The method 1000 may comprise inputting 1062 the data images 201, 202, 203, 204, to an artificial intelligence application for subsequent detection 1063 of deviations in the process parameters. Based on combinations of packaging unit data in the associated images 201, 202, in some examples in combination with physical appearance, such application may be trained on how to adapt the manufacturing parameters for different scenarios, so that a pattern of how to recognize and develop/adjust the parameters can be learned, e.g. by extrapolating from the scenarios during learning phase. Such process can be applied to any point in the process line. The AI application of the relevant machine can thus continuously evaluate the result of process carried out and adapt its set of process parameters. This is enabled by the unique tracing of individual packaging units 301′, 302′, 303′, 304′, by building associated data images 201, 202, 203, 204, as described above. Machine hierarchy may be taken into account. E.g. the machine may at a higher level evaluate each process application as an ability, analogous to a type of skill, where each skill may be evaluated and possibly prioritized for optimization to increase the overall throughput. The artificial intelligence application may comprise a machine learning-based model.
[0040] A computer program product is provided comprising instructions which, when the program is executed by a computer, cause the computer to carry out the steps of the method 1000 as described above.
[0041] A packaging machine is provided comprising a system 200 as described above in relation to
[0042] From the description above follows that, although various embodiments of the invention have been described and shown, the invention is not restricted thereto, but may also be embodied in other ways within the scope of the subject-matter defined in the following claims.