METHOD FOR PRODUCT GUIDANCE IN A FILING SYSTEM AND FILLING SYSTEM FOR GLASS BOTTLES

Abstract

A method for product guidance in a filling system for glass bottles, and a corresponding production system are described. Empties parameters for filling the empty glass bottles are measured in an automated manner. Initial data for filling a liquid product into the bottles is acquired and stored. Fulls parameters are measured when the bottles are filled, where machine error states are also detected, and respective results data acquired relating to the filling process are savored and individually associated with the empty bottles. At least one lead-out criterion applicable in the downstream production operation is calculated for deciding whether or not to lead-out faulty empty bottles or filled bottles based on the initial data and results data stored. The lead-out criterion is additionally updated in an automated manner while taking into consideration the acquired initial data and results data.

Claims

1. A method for product guidance in a filling system, where empties parameters for filling empty glass bottles provided are measured in an automated manner and initial data for filling a liquid product into said empty Mass bottles is acquired and stored, where fulls parameters are measured when filled bottles, produced are filled, machine error states that occur during the filling process are detected in an automated manner, and respectively acquired results data of the filling process are individually associated with said empty glass bottles and stored, where at least one lead-out criterion applicable in a downstream production operation is calculated for deciding whether or not to lead out faulty empty bottles or filled bottles based on a data analysis of said initial data and results data stored, and where a calculation of said at least one lead-out criterion is updated taking into consideration initial data and results data acquired during production.

2. The method according to claim I, where said initial data and said results data acquired are incorporated into the production operation updated in a manual and/or automated manner.

3. The method according to claim 1, where machine parameters, of a filling machine tor producing said filled bottles, and/or a closing machine for closing said filled bottles are adapted to optimize a product quality obtained.

4. The method according to claim 1, where said at least one lead-out criterion is optimized in an automated manner in such a way that a proportionate frequency of permissible values of said fulls parameters predicted by way of said data analysis increases.

5. The method according to claim 1, where said data analysis comprises data mining.

6. The method according to claim 1, where fulfilling said lead-out criterion triggers: leading said associated empty bottles out upstream of a filling element provided for this purpose; passing said empty bottles through said filling element without filling it, but closing it and leading said empty bottles out; or producing and leading out a closed filled bottle.

7. The method according claim 1, where respective target ranges of said empties parameters are defined based on said data analysis, and where said at least one lead-out criterion specifies which and/or to which extent initial data of an empty bottle examined may deviate from said respective target ranges.

8. The method according to claim 7, where said respective target ranges and/or said at least one lead-out criterion is/are updated based on a progressive accumulation of initial data and results data acquired.

9. The method according to claim 7, where several sets of parameters are taken into consideration in the data analysis, each of which comprises associated empties parameters and fulls parameters, and where deviations of measured empties parameters from their target ranges are included in a weighted manner.

10. The method according to claim 1, where said empties parameters indicate at least three of the following properties and/or states of said respective empty bottles: correct type of bottle, extent of scuffing, fouling of and/or damage to a side wall; fouling of, rust deposits, and/or damage to side mouth regions/closure threads; fouling of and/or damage to sealing surfaces; fouling of and/or damage to base regions; and/or a presence of lye residues or other liquid in the interior.

11. The method according to claim 3, where at least some of said empties parameters are detected by imaging upstream of and/or in said inlet region of a filling machine.

12. The method according to claim 10, where said fulls parameters indicate at least two of the following properties/states of said filled bottles: a filling level of said filled product; absence, damage to, or improper fit of an attached closure; tightness of the closure.

13. The method according to claim 3, where said machine error states comprise: bottle fracture at an associated filling element; bottle fracture downstream of said associated filling element; insufficient evacuation of said empty glass bottle at said filling element; and/or force/torque incorrect when applying an associated closure.

14. A filling system with a filling machine for empty glass bottles and an associated closing machine for filled bottles produced therefrom and further comprising: at least one lead-out device for empty glass bottles arranged upstream of said filling machine; at least one lead-out device for filled bottles and/or closed empty bottles arranged downstream of said closing machine; inspection units for said empty bottles and said filled bottles for collecting initial data and results data using the method according to claim 7; and a control device for triggering said at least one lead-out device on the basis of at least one lead-out criterion calculated using the method according to claim 7.

15. The method in accordance with claim 3, wherein the machine is an upstream rinsing station for rinsing said empty glass bottles.

16. The method in accordance with claim 4, where the predicted proportionate frequency of machine error states decreases.

17. The method in accordance with claim 5, wherein the data analysis is an association analysis, and/or a regression analysis, and/or a data classification.

18. The method in accordance with claim 9, wherein the fulls parameters and empties parameters are weighted dynamically on the basis of initial data and results data acquired, in defining said at least one lead-out criterion.

19. The method in accordance with claim 10, where said empties parameters indicate at least five of the properties and/or states of said respective empty bottles.

20. The method in accordance with claim 11, where said at least some of said empties parameters are detected by imaging upstream of and/or in said inlet region of a filling machine upstream, downstream of a rinsing station for rinsing said empty bottle.

Description

BRIEF DESCRIPTION OF THE FIGURES

[0035] An embodiment of the invention is illustrated by drawing. FIG. 1. shows a schematic top view onto a production system with associated data streams.

DETAILED DESCRIPTION

[0036] As shown in FIG. 1, the method according to the invention for product guidance/production control can be carried out in a filling system 100 for glass bottles. Filling system 100 accordingly comprises inspection units 1-3 for empty bottles, inspection units 4-6 for filled bottles, lead-out devices 7-9 for empty bottles, and lead-out devices 10, 11 for filled bottles, each illustrated by way of example. Filling system 100 described can also include a purging/rinsing station 12 for rinsing the empty bottles intended for filling Present in any case is a filling machine 13 of, for example, a rotary design with a plurality of filling elements (not shown) for filling a liquid product, such as a beverage, into the empty bottles and a closing machine 14 for closing the filled bottles with closing caps, for example, crown caps or screw caps. Furthermore, a labeling machine 15 for labeling properly filled and closed filled bottles can be part of filling system 100.

[0037] Closing machine 14 can be preceded by an inspection unit 16 for closing caps and a lead-out device 17 for closing caps identified as being faulty.

[0038] Filling system 100 further comprises a control device 20 which controls lead-out devices 7-11 on the basis of the lead-out criteria described below.

[0039] The production control device is indicated schematically by way of example by way of seven empty bottles A G supplied/provided and/or filled bottles A′, C′, F′ and G′ produced therefrom. Black circle fillings indicate negative inspection results.

[0040] Accordingly, due to negative inspection results in at least one of inspection units 1-3 arranged upstream of filling machine 13 and on the inlet side thereof, two empty bottles B, D are led out at first and/or second lead-out device 7, 8 upstream of filling machine 13.

[0041] Empty bottle E, on the other hand, is initially passed empty through filling machine 13 despite at least one negative inspection result in inspection units 1-3 on the inlet side and only after it has been closed is led out at third lead-out device 9 arranged downstream of closing machine 14 and on the outlet side thereof onto a lead-out lane into a collection container (each not shown) or the like.

[0042] Four empty bottles A, C, F and G (not all of which are designated separately in FIG. 1) pass first, second, and third inspection units 1-3 with correct inspection results and are consequently filled with product and closed; this corresponds to the regular production/manufacture of filled bottles A′, C′, F′ and G′.

[0043] In first inspection unit 1 on the inlet side upstream of purging/rinsing station 12, a first empties parameter LP1 is measured/verified, for example, the presence and/or extent of scuffing caused by wear on empty bottles A-G.

[0044] Downstream of rinsing station 12, a second and third empties parameter LP2, LP3 are measured in second and third inspection unit 2, 3 on the inlet side, for example, the presence of residual lye or other liquid in (remaining) empty bottles A and C-G and the extent of any possibly given sidewall fouling of empty bottles A and C-G.

[0045] The type and number of inspection units on the inlet side can differ from the example described and, for example, be modularly adapted to the empty bottles to be processed and/or to control certain treatments carried out upstream.

[0046] First inspection unit 1 delivers at least one measured value of first empty container parameter LP1 in the form of first initial data IDI for each empty bottle AG measured there. Second and third inspection units 2, 3 correspondingly deliver measured values of second and third empty container parameters LP2, LP3 in the form of second and third initial data ID2, ID3 for each empty bottle A, C-G measured there. They are each transmitted to control device 20. First initial data IDI is associated with all empty bottles A-G, second and third initial data ID2, ID3 with remaining empty bottles A and C-G.

[0047] In fourth and fifth inspection units 4, 5 disposed downstream of filling machine 13 and on the outlet side thereof, closed filled bottles A′, C′, F′, G′ (not all of which are illustrated as a circle) are examined with regard to fulls parameters VP1, VP2 created during the filling process, for example, a filling level of the product in filled bottles A′, C′, F′, G′ and the correctness of their closure.

[0048] Fourth inspection unit 4 delivers at least one measured value of first fulls parameter VP1 in the form of first results data ED1 for each filled bottle measured there, fifth inspection unit 5 correspondingly delivers at least one measured value of second fulls parameter VP2 in the form of second results data ED2. They are each transmitted to control device 20.

[0049] First and second results data ED1, ED2 are associated as filled bottles A′, C′, F′, G′ with filled empty bottles A, C, F, G and therefore with their initial data IDI-ID2.

[0050] Empty bottle E could optionally be processed incompletely when/after being passed through filling machine 13, for example, only by closing it, and be inspected in fourth and/or fifth inspection unit 4, 5 with regard to at least one of fulls parameters VP1, VP2 or with regard to one parameter only relevant for the closing or another treatment step performed. In this way, for example, results data ED2 for empty bottle E can be acquired as in a corresponding filled bottle inspection. This results data ED2 can then also be stored in control device 20 and associated with empty bottle E and its stored initial data ID1-ID3.

[0051] In sixth inspection unit 6 on the outlet side of labeling machine 15, labeled filled bottles A′, C′, F′ are measured with regard to at least one fulls parameter VP3 that is relevant after labeling, for example, for the correct label placement or the like Results data ED3 acquired there can then likewise be stored in control device 20 and associated with underlying empty bottle A, C, F as well as its stored initial data ID1-ID3.

[0052] It is also schematically indicated that, for example, filling machine 13 and/or closing machine 14 and/or the purging/rinsing station 12 and/or labeling machine 15 can be monitored with regard to the occurrence of machine error states FZ1, FZ2, for example, with regard to the occurrence of a bottle facture in the inlet and/or outlet of filling machine 13 and/or a leak detected in the region of filling machine 13 or closing machine 14 and/or incorrect closing forces/torques.

[0053] In a broader sense, a machine error state can be a failure to recognize or reject fouled or otherwise contaminated containers. For example, a shard in a bottle that was not recognized during the empty bottle inspection (for example in one of inspection units 1-3) can still be recognized during a subsequent filled bottle inspection (for example in one of inspection units 4 and 5).

[0054] In the presence of a machine error state FZ1, FZ2, associated fourth or fifth results data ED4, EDS are stored in control device 20 and associated with the respective empty bottle concerned and its initial data ID1-ID3 stored.

[0055] Initial data, results data, and/or error states may be detected by imaging and/or in a sensor-based manner.

[0056] During the production operation, control device 20 carries out a data analysis at predetermined intervals on the basis of initial data ID1-ID3 collected for a plurality of empty bottles and results data ED1-ED5 available for this. The data analysis comprises, for example, data mining with classification and/or regression analysis and/or association analysis and can be based on self-learning algorithms in the sense of artificial intelligence.

[0057] Based on the data analysis, lead-out criteria AK1-AK5 are calculated in an automated manner and determine which initial data ID1-ID3 or which results data ED1-ED5 cause empty bottles/filled bottles to be led out at one of lead-out devices 7-11.

[0058] A first lead-out criterion AK1 is used, for example, to decide whether an empty bottle recognized as being faulty in first inspection unit 1 is to be separated from the product flow by first lead-out device 7. In the example shown, this is the case for empty bottle B, as is shown schematically by a lead-out arrow. Empty bottle B fulfills first lead-out criterion AK1, for example, if initial data ID1 measured for empty bottle B deviates in an impermissible manner from a target value SW1 of associated empties parameter LP1 calculated in control device 20 on the basis of the data analysis.

[0059] After empty bottle B has been led out at first lead-out device 7, triggered by first lead-out criterion AK1, no further initial data ID2, ID3 or results data ED1-ED5 can be collected for this empty bottle B.

[0060] In order to optimize the production process as comprehensively as possible, however, it is desirable to possibly acquire additional initial data ID2, ID3 and/or results data ED1-ED5 for cosmetically faulty empty bottles in order to establish or to specify and/or weigh correlations between initial data ID2, ID3 and/or results data ED1-ED5. The data analysis, and with it lead-out criteria AK1-AK5, can then be dynamically optimized on this basis.

[0061] To avoid the spread of germs, however, it must be ensured that no contaminated empty bottles reach filling machine 13. Damage to filling system 100, production interruptions, and product losses are also to be avoided as comprehensively as possible. As a result, lead-out criteria AK1-AK5 are continuously optimized in order to meet the requirements for a meaningful data analysis as well as the requirements for an economical and smooth production process and the desired product quality.

[0062] Under this premise, as many empty bottles as possible are not led out at first lead-out device 7, but, as in the case of empty bottles A and C-G, are fed to purging/rinsing station 12 and cleaned/rinsed there for subsequent filling. Empty bottles A and C-G are thereafter inspected in second and third inspection units 2, 3 and their initial data ID2 and ID3 thus acquired is transmitted to control device 20.

[0063] It is verified for each of empty bottles A, C-G inspected in this manner whether a second lead-out criterion AK2 previously calculated in control device 20 on the basis of the data analysis is fulfilled. It is fulfilled, for example, if at least second initial data ID2 or third initial data ID3 of a specific empty bottle A, C-G deviates in an impermissible manner from a target value SW2, SW3 of respective associated empties parameters LP2, LP3. In the example shown, this is the case with empty bottle D. It is therefore separated from the product flow by second lead-out device 8.

[0064] Each lead-out criterion AK1-AK5 can be calculated almost at random on the basis of previously collected initial data ID1-ID3 and individually associated results data ED1-ED5. For example, if it is found that a certain constellation of initial data IDI-ID3 correlates with results data ED1-ED5 that is negative for product quality and/or harmful to the production process.

[0065] First and/or second lead-out criterion AK1, AK2 would prevent a certain empty bottle from being forwarded to rinsing station 12, filling machine 13, and closing machine 14, and/or labeling machine 15 in the event of such a negative prognosis in that the empty bottle concerned is led out at first or second lead-out device 7, 8. Correspondingly, lead-out criteria AK1-AK5 can also be relaxed if this is concluded from an updated data analysis.

[0066] Initial data ID1-ID3 of empty bottles A and C-G do not fulfill second lead-out criterion AK2, so that they are fed to filling machine 13. It is schematically indicated in the region of filling machine 13 that, an empty bottle E that was not previously led out does not fulfill second lead-out criterion AK2 due to its initial data ID1-ID3, but does fulfill a third lead-out criterion AK3, whereby empty bottle E is separated from the product stream downstream of filling machine 13 and closing machine 14 at third lead-out device 9. Empty bottle E can therefore either be led out upstream of filling machine 13 or channeled empty through filling machine 13, closed in closing machine 14, and separated after inspection of the closure produced. Other inspections would also be conceivable at fourth and/or fifth inspection unit 4, 5. In this way, first and/or second results data ED1, ED2 for possibly closed empty bottle E usable within the framework of the data analysis could be acquired. Empty bottle E, which has not been treated or treated in part, could also be fed to labeling machine 15 and downstream inspection unit 6 in order to acquire further results data ED3.

[0067] All empty bottles whose initial data IDI ID3 fulfill neither first nor the second lead-out criteria AK1, AK2, presently empty bottles A, C, F and G, are processed in filling machine 13 to become filled bottles, closed in closing machine 14, and inspected in fourth and fifth Inspection unit 4, 5. First and second results data ED1, ED2 acquired in this manner is associated with underlying empty bottles A, C, F and G and can be correlated in the data analysis both with one another as well as with associated initial data IDI-ID3 of empty bottles A, C, F and G.

[0068] If a fourth lead-out criterion AK4 is fulfilled for the filled bottles examined in this manner, for example, for the reason that first results data IDI and/or second results data ED2 deviate in an impermissible manner from a fourth or fifth target value SW4, SW5 of respectively associated fulls parameter VP1, VP2, then the respective filled bottles, in the example filled bottle G′, are separated from the product flow at fourth lead-out device 10.

[0069] Correctly filled and closed filled bottles A′, C′, and F′ are fed to labeling machine 15 and provided there with a label and/or are printed on directly. Filled bottles A′, C′, F′ that have been labeled/printed on are subsequently examined, for example, in a fifth inspection unit 6. Third results data ED3 acquired in the process are also transmitted to control device 20.

[0070] For the sake of completeness, a fifth lead-out device 11 arranged downstream of labeling machine 15 is also indicated schematically. It leads out incorrectly labeled/printed filled bottles (or possibly also partially treated empty bottles) for which a fifth lead-out criterion AK5 is fulfilled, for example, based on a comparison of third results data ED3 with a sixth target value SW6 of associated third fulls parameter VP3.

[0071] Continuously monitored machine error states FZ1, FZ2 are optionally also transmitted to control device 20 with an association with the concerned or underlying empty bottle in order to take them into consideration in the data analysis in terms of fourth and fifth results data ED4, EDS. All results data ED1-ED5 can thus be correlated with one another with individual or groups of initial data ID1-ID3 individually for single empty bottles and/or for groups of empty bottles.

[0072] During ongoing production, initial data ID1-ID3 and results data ED1-ED5, to the extent available for the individual empty bottles and filled bottles, are associated with one another and accumulated. With the data analysis, for example, in the sense of data mining, correlations between individual empties parameters LP1-LP3, fulls parameters VP1-VP3, and/or machine error states FZ1, FZ2 can be calculated and continuously updated and, possibly rendered more precise by acquiring initial data and results data during the production operation.

[0073] On this basis, individual lead-out criteria AK1-AK5 that subsequently apply in the production operation can be continuously recalculated in order to lead out individual empty bottles in a selective manner in such a way that production interruptions and/or damage can be prevented and as much information as possible about correlations between initial data and results data can be established at the same time.

[0074] Individual empties parameters LP1-LP3 or initial data ID1-ID3 associated therewith can be processed in a weighted manner depending on the effect on results data ED1-EDS. Such a weighting of parameters and/or sets of parameters can also be continuously adapted during ongoing production operations in the sense of self-optimization of filling system 100 in order to produce as many high-quality filled bottles as possible from the empty bottles and/or to improve the informative value of the data analysis.

[0075] In certain embodiments, any suitable algorithms can be used in control device 20 for processing initial data ID1-ID3 and results data ED1-ED5, e.g., to enable machine-internal optimization and/or machine-internal learning in the sense of artificial intelligence.

[0076] It is crucial that lead-out criteria AK1-AK5 can be dynamically adapted in dependence of the accumulating and/or updated data volume with mutually associated initial data of the empty bottle and results data of the filled bottles produced therefrom.

[0077] The above-described data analysis and control process can also include inspection unit 16 for closure caps that is upstream of closing machine 14 and lead-out device 17 for closure caps that have been identified as being faulty. For example, inspection unit 16 can supply at least one measured value of a further empties parameter in the form of further initial data for each closure cap measured there. Likewise, a separate lead-out criterion can be calculated for lead-out device 17 and used in principle in the same manner for closure caps as was described above for lead-out devices 7-11.

[0078] Separately illustrated lead-out devices, such as, for example, lead-out devices 9, 10 downstream of sealing machine 14, can also be combined with one another. This means that different lead-out criteria can be calculated for a specific lead-out device. For example, third lead-out criterion AK3 could be used to separate empty bottles treated in part onto a specific lead-out lane, the fourth reject criterion to separate faulty filled bottles onto another lead-out lane, e.g., in a single or in several lead-out devices.

[0079] Machine parameters MP, for example, of purging/rinsing station 12, of filling machine 13, of closing machine 14, and/or of labeling machine 15 can be continuously adapted on the basis of acquired initial data ID1-ID3 and results data ED1-ED5 to optimize the product quality.

[0080] Initial data ID1-ID3 and results data ED1-ED5 acquired can flow into the production operation both through manually triggered and also through automated updating of lead-out criteria AK1-AK5 and/or machine parameters MP.

[0081] Embodiments of the disclosure may simultaneously enable the minimization of machine error states and quality optimization when filling filled bottles during ongoing operations.

[0082] The following claims particularly point out certain combinations and sub-combinations regarded as novel and non-obvious. These claims may refer to “an” element or “a first” element or the equivalent thereof. Such claims should be understood to include incorporation of one or more such elements, neither requiring nor excluding two or more such elements. Other combinations and sub-combinations of the disclosed features, functions, elements, and/or properties may be claimed through amendment of the present claims or through presentation of new claims in this or a related application. Such claims, whether broader, narrower, equal, or different in scope to the original claims, also are regarded as included within the subject matter of the present disclosure.