DEVICE AND METHOD FOR VISUALIZING OR ASSESSING A PROCESS STATE

Abstract

A device for monitoring a production facility includes a computing unit, at least one sensor, a memory unit, and an output device. In the memory unit, in each of at least one process variable set, at least three possible process states are stored and at least one algorithm is stored by which the one of the different possible process states actually present can be calculated, the possible process states that differ in relation to the respective process variable set are classified according to whether measures are necessary or recommended, the commands by the computing unit prompt it to execute the associated algorithm and thus to calculate which of the different possible process states is actually present and to check whether the actually present process state is classified as such a process state, to generate and output an electronic message depending on the calculated process state.

Claims

1. A device for monitoring a production facility containing a moulding machine functioning in moulding cycles and optionally at least one peripheral device, with: a computing unit, at least one sensor, by means of which at least one actual value (P.sub.1,actual, P.sub.2,actual, . . . , P.sub.m,actual) of at least one process variable (P.sub.1, P.sub.2, . . . , P.sub.m) of the production facility can be determined in time-continuous or time-discrete manner, wherein the at least one sensor, is in or can be brought into data connection with the computing unit, a memory unit, which is in or can be brought into data connection with the computing unit, wherein a computer program containing commands is stored in the memory unit, an output device, with which the computing unit is in or can be brought into data connection, wherein, in a memory unit which is in or can be brought into data connection with the computing unit, in relation to at least one process variable set, comprising at least two different process variables (P.sub.1, P.sub.2, . . . , P.sub.m) of the production facility or at least one process variable (P.sub.1, P.sub.2, . . . , P.sub.m) with at least one derived variable (G.sub.1, G.sub.2, . . . , G.sub.n), in each case at least three possible process states (Z.sub.1, Z.sub.2, . . . , Z.sub.q) of the production facility are stored and, in relation to each process variable set, at least one algorithm (A.sub.1, A.sub.2, . . . , A.sub.t) is stored by which, using actual values (P.sub.1,actual, P.sub.2,actual, . . . , P.sub.m,actual) of at least two process variables (P.sub.1, P.sub.2, . . . , P.sub.m) or one actual value (P.sub.1,actual, P.sub.2,actual, . . . , P.sub.m,actual) of at least one process variable (P.sub.1, P.sub.2, . . . , P.sub.m) and one actual value (G.sub.1,actual, G.sub.2,actual, . . . , G.sub.n,actual) of at least one derived variable (G.sub.1, G.sub.2, . . . , G.sub.n) and at least one additional parameter (K.sub.1, K.sub.2, . . . , K.sub.v) which is different from the actual value (P.sub.1,actual, P.sub.2,actual, . . . , P.sub.n,actual) of the respective process variable (P.sub.1, P.sub.2, . . . , P.sub.m) and from the actual value (G.sub.1,actual, G.sub.2,actual, . . . , G.sub.n,actual) of the respective derived variable (G.sub.1, G.sub.2, . . . , G.sub.n), it can be calculated which of the possible process states (Z.sub.1, Z.sub.2, . . . , Z.sub.q) that differ in relation to the respective process variable set (P) is actually present, the possible process states (Z.sub.1, Z.sub.2, . . . , Z.sub.q) that differ in relation to the respective process variable set (P) are classified according to whether measures which bring about an alteration of at least one process variable (P.sub.1, P.sub.2, . . . , P.sub.m) and/or at least one derived variable (G.sub.1, G.sub.2, . . . , G.sub.n) are necessary or recommended, wherein, in relation to each process variable set, at least one process state (Z.sub.1, Z.sub.2, . . . , Z.sub.q) is classified such that no measures are necessary or recommended and at least one process state (Z.sub.1, Z.sub.2, . . . , Z.sub.q) is classified such that measures are necessary or recommended, the commands during the execution of the computer program by the computing unit prompt it to execute, in relation to the respective process variable set, the associated at least one algorithm (A.sub.1, A.sub.2, . . . , A.sub.t) and thus, using actual values (P.sub.1,actual, P.sub.2,actual, . . . , P.sub.m,actual) of the at least two process variables (P.sub.1, P.sub.2, . . . , P.sub.m) or the actual value (P.sub.1,actual, P.sub.2,actual, . . . , P.sub.m,actual) of the at least one process variable (P.sub.1, P.sub.2, . . . , P.sub.m) and the actual value (G.sub.1,actual, G.sub.2,actual, . . . , G.sub.m,actual) of the at least one derived variable (G.sub.1, G.sub.2, . . . , G.sub.n) and the at least one additional parameter (K.sub.1, K.sub.2, . . . , K.sub.v), to calculate which of the possible process states (Z.sub.1, Z.sub.2, . . . , Z.sub.q) of the production facility that differ in relation to the respective process variable set is actually present and to check whether the actually present process state (Z.sub.1, Z.sub.2, . . . , Z.sub.q) is classified as such a process state (Z.sub.1, Z.sub.2, . . . , Z.sub.q) for which a measure which brings about an alteration of the respective process variable set is necessary or recommended, for the case where a measure is necessary or recommended in relation to the actually present process state (Z.sub.1, Z.sub.2, . . . , Z.sub.q) because of its classification, to generate an electronic message (T) depending on the calculated process state (Z.sub.1, Z.sub.2, . . . , Z.sub.q) and to output it by means of the output device.

2. The device according to claim 1, wherein the electronic message contains an item of information as to: which measure is necessary or recommended and/or which of the possible process states (Z.sub.1, Z.sub.2, . . . , Z.sub.q) that differ in relation to the process variable set is actually present.

3. The device according to claim 1, wherein at least one additional parameter (K.sub.1, K.sub.2, . . . , K.sub.v) and/or at least one process variable (P.sub.1, P.sub.2, . . . , P.sub.m) and/or at least one derived variable (G.sub.1, G.sub.2, . . . , G.sub.n) from at least one preceding moulding cycle can be used for the execution of the at least one algorithm (A.sub.1, A.sub.2, . . . , A.sub.t).

4. The device according to claim 1, wherein the at least one process state (Z.sub.1, Z.sub.2, . . . , Z.sub.q) and/or a change in the at least one process state (Z.sub.1, Z.sub.2, . . . , Z.sub.q) is displayed in the form of the electronic message.

5. The device according to claim 1, wherein at least two algorithms can be used in parallel for the calculation of the actually present process state (Z.sub.1, Z.sub.2, . . . , Z.sub.q) and/or the classification of the actually present process state (Z.sub.1, Z.sub.2, . . . , Z.sub.q).

6. The device according to claim 1, wherein, for the case where no measure is necessary or recommended in relation to the actually present process state (Z.sub.1, Z.sub.2, . . . , Z.sub.q) because of its classification, the commands during the execution of the computer program (5) by the computing unit prompt it either not to output a message or to generate an electronic message and output it by means of the output device, wherein the electronic message contains an item of information as to which of the possible process states (Z.sub.1, Z.sub.2, . . . , Z.sub.q) that differ in relation to the respective process variable set is actually present and/or an item of information that no measure is necessary or recommended.

7. The device according to claim 1, wherein at least one additional parameter (K.sub.1, K.sub.2, . . . , K.sub.v) relates to an actual value (P.sub.1,actual, P.sub.2,actual, . . . , P.sub.m,actual) of the associated process variable (P.sub.1, P.sub.2, . . . , P.sub.m) and/or to an actual value (G.sub.1,actual, G.sub.2,actual, . . . , G.sub.n,actual) of the associated derived variable (G.sub.1, G.sub.2, . . . , G.sub.n) from at least one preceding moulding cycle of the moulding machine, wherein it is preferably provided that a historical progression of the actual value (P.sub.1,actual, P.sub.2,actual, . . . , P.sub.m,actual) of the associated process variable (P.sub.1, P.sub.2, . . . , P.sub.m) and/or the actual value (G.sub.1,actual, G.sub.2,actual, . . . , G.sub.n,actual) of the associated derived variable (G.sub.1, G.sub.2, . . . , G.sub.n) is calculated from a plurality of actual values (P.sub.1,actual, P.sub.2,actual, . . . , P.sub.m,actual) of the associated process variable (P.sub.1, P.sub.2, . . . , P.sub.m) and/or from a plurality of actual values (G.sub.1,actual, G.sub.2,actual, . . . , G.sub.n,actual) of the associated derived variable (G.sub.1, G.sub.2, . . . , G.sub.n) from a plurality of preceding moulding cycles.

8. The device according to claim 1, wherein at least one additional parameter (K.sub.1, K.sub.2 . . . , K.sub.v) is selected from the list below: a target value (P.sub.1,target, P.sub.2,target, . . . , P.sub.m,target) of at least one process variable (P.sub.1, P.sub.2, . . . , P.sub.m), optionally the process variable (P.sub.1, P.sub.2, . . . , P.sub.m) in relation to which the actually present process state (Z.sub.1, Z.sub.2, . . . , Z.sub.q) is to be calculated, a target value (G.sub.1,target, G.sub.2,target, . . . , G.sub.n,target) of at least one derived variable (G.sub.1, G.sub.2, . . . , G.sub.n), optionally the derived variable (G.sub.1, G.sub.2, . . . , G.sub.n) in relation to which the actually present process state (Z.sub.1, Z.sub.2, . . . , Z.sub.q) is to be calculated, an actual value (P.sub.1,actual, P.sub.2,actual, . . . , P.sub.m,actual) of at least one process variable (P.sub.1, P.sub.2, . . . , P.sub.m) from at least one preceding cycle, an actual value (G.sub.1,actual, G.sub.2,actual, . . . , G.sub.m,actual) of a derived variable (G.sub.1, G.sub.2, . . . , G.sub.n) from at least one preceding cycle, a reference value (P.sub.1,ref, P.sub.2,ref, . . . , P.sub.m,ref) of at least one process variable (P.sub.1, P.sub.2, . . . , P.sub.m), optionally the process variable (P.sub.1, P.sub.2, . . . , P.sub.m) in relation to which the actually present process state (Z.sub.1, Z.sub.2, . . . , Z.sub.q) is to be calculated, a reference value (G.sub.1,ref, G.sub.2,ref, . . . , G.sub.n,ref) of at least one derived variable (G.sub.1, G.sub.2, . . . , G.sub.n), optionally the derived variable (G.sub.1, G.sub.2, . . . , G.sub.n) in relation to which the actually present process state (Z.sub.1, Z.sub.2, . . . , Z.sub.q) is to be calculated, a tolerance range (P.sub.1, P.sub.2, . . . , P.sub.m) of at least one process variable (P.sub.1, P.sub.2, . . . , P.sub.m), optionally the process variable (P.sub.1, P.sub.2, . . . , P.sub.m) in relation to which the actually present process state (Z.sub.1, Z.sub.2, . . . , Z.sub.q) is to be calculated, a tolerance range (G.sub.1, G.sub.2, . . . , G.sub.n) of at least one derived variable (G.sub.1, G.sub.2, . . . , G.sub.n), optionally the derived variable (G.sub.1, G.sub.2, . . . , G.sub.n) in relation to which the actually present process state (Z.sub.1, Z.sub.2, . . . , Z.sub.q) is to be calculated, an auxiliary variable, preferably a counter variable, a geometric parameter of the moulding machine and/or optionally of the at least one peripheral device, component-specific parameters of the moulding machine and/or optionally of the at least one peripheral device, performance data of the moulding machine and/or optionally of the at least one peripheral device, parameters of a raw material.

9. The device according to claim 1, wherein the at least one derived variable (G.sub.1, G.sub.2, . . . , G.sub.n) is calculated from the actual values (P.sub.1,actual, P.sub.2,actual, . . . , P.sub.m,actual) of at least one process variable (P.sub.1, P.sub.2, . . . , P.sub.m) of a current moulding cycle and/or of past moulding cycles and optionally of the at least one additional parameter (K.sub.1, K.sub.2, . . . , K.sub.v) and/or in relation to a value relating to a drift.

10. The device according to claim 9, wherein the at least one derived variable (G.sub.1, G.sub.2, . . . , G.sub.n) is selected from the list below: a value relating to a drift of a process variable (P.sub.1, P.sub.2, . . . , P.sub.m), a statistical coefficient of the actual values of a process variable (P.sub.1, P.sub.2, . . . , P.sub.m) of a current moulding cycle and/or of past moulding cycles.

11. The device according to claim 1, wherein the at least one algorithm (A.sub.1, A.sub.2, . . . , A.sub.t) comprises at least one hypothesis (H.sub.1, H.sub.2, . . . , H.sub.r), wherein the at least one hypothesis (H.sub.1, H.sub.2, . . . , H.sub.r) in relation to the actually present at least one process state (Z.sub.1, Z.sub.2, . . . , Z.sub.q) and/or the change in the at least one process state (Z.sub.1, Z.sub.2, . . . , Z.sub.q) represents a possible diagnosis in relation to a cause of the presence of the at least one process state (Z.sub.1, Z.sub.2, . . . , Z.sub.q) and/or the change in the at least one process state (Z.sub.1, Z.sub.2, . . . , Z.sub.q).

12. The device according to claim 11, wherein the possible diagnosis can be generated by the at least one hypothesis (H.sub.1, H.sub.2, . . . , H.sub.r) on the basis of the at least one algorithm present (A.sub.1, A.sub.2, . . . , A.sub.t) and at least one event (E.sub.1, E.sub.2, . . . , E.sub.o) and/or can be modified depending on at least one preceding moulding cycle.

13. The device according to claim 11, wherein at least one electronic message can be displayed, which presents the at least one diagnosis in the form of an electronic message and/or which displays the applicability and/or non-applicability of the at least one hypothesis (H.sub.1, H.sub.2, . . . , H.sub.r) and/or the at least one process state (Z.sub.1, Z.sub.2, . . . , Z.sub.q).

14. The device according to claim 11, wherein at least two hypotheses (H.sub.1, H.sub.2, . . . , H.sub.r) can be used and/or displayed in parallel for the diagnosis of the actually present at least one process state (Z.sub.1, Z.sub.2, . . . , Z.sub.q) and/or a change in the at least one process state (Z.sub.1, Z.sub.2, . . . , Z.sub.q).

15. The device according to claim 1, wherein the electronic message is generated by the computing unit in relation to at least one of the possible process states (Z.sub.1, Z.sub.2, . . . , Z.sub.q) with at least one fixed message element and at least one variable message element, wherein it is preferably provided that the at least one variable message element contains at least one numerical value of at least one process variable (P.sub.1, P.sub.2, . . . , P.sub.m) and/or at least one derived variable (G.sub.1, G.sub.2, . . . , G.sub.n) and/or at least one additional parameter (K.sub.1, K.sub.2, . . . , K.sub.n) or a graphic representation of a temporal progression of at least one numerical value of at least one process variable (P.sub.1, P.sub.2, . . . , P.sub.m) and/or at least one derived variable (G.sub.1, G.sub.2, . . . , G.sub.n) and/or at least one additional parameter (K.sub.1, K.sub.2, . . . , K.sub.v).

16. Device according to claim 1, wherein the electronic message contains at least one numerical value of at least one process variable (P.sub.1, P.sub.2, . . . , P.sub.m) and/or at least one derived variable (G.sub.1, G.sub.2, . . . , G.sub.n) and/or at least one additional parameter (K.sub.1, K.sub.2, . . . , K.sub.v).

17. The device according to claim 1, wherein the electronic message contains a graphic representation of a temporal progression of at least one numerical value of at least one process variable (P.sub.1, P.sub.2, . . . , P.sub.m) and/or at least one derived variable (G.sub.1, G.sub.2, . . . , G.sub.n) and/or at least one additional parameter (K.sub.1, K.sub.2, . . . , K.sub.v).

18. The device according to claim 1, wherein the electronic message contains at least one message element in the form of a plain text notification and/or a graphic or an image and/or an acoustic notification and/or a non-textual, visual notification.

19. A production facility with a moulding machine functioning in moulding cycles and optionally at least one peripheral device and a device according to claim 1.

20. A computer program product, comprising commands which, when executed by a computing unit, prompt it, for a production facility containing a moulding machine functioning in moulding cycles and optionally at least one peripheral device, from a memory unit which is in or can be brought into data connection with the computing unit, in relation to at least one process variable set of the production facility, to retrieve in each case at least three possible process states (Z.sub.1, Z.sub.2, . . . , Z.sub.q) of the production facility and, in relation to each process variable set, to retrieve at least one algorithm (A.sub.1, A.sub.2, . . . , A.sub.t) by which, using actual values (P.sub.1,actual, P.sub.2,actual, . . . , P.sub.m,actual) of at least two process variables (P.sub.1, P.sub.2, . . . , P.sub.m) or one actual value (P.sub.1,actual, P.sub.2,actual, . . . , P.sub.m,actual) of at least one process variable (P.sub.1, P.sub.2, . . . , P.sub.m) and one actual value (G.sub.1,actual, G.sub.2,actual, . . . , G.sub.n,actual) of the respective derived variable (G.sub.1, G.sub.2, . . . , G.sub.n) and at least one additional parameter (K.sub.1, K.sub.2, . . . , K.sub.v) which is different from the actual value (P.sub.1,actual, P.sub.2,actual, . . . , P.sub.m,actual) of the respective process variable (P.sub.1, P.sub.2, . . . , P.sub.m) and from the actual value (G.sub.1,actual, G.sub.2,actual, . . . , G.sub.n,actual) of the respective derived variable (G.sub.1, G.sub.2, . . . , G.sub.n), it can be calculated which of the possible process states (Z.sub.1, Z.sub.2, . . . , Z.sub.q) of the production facility that differ in relation to the respective process variable set (P) is actually present, wherein the possible process states (Z.sub.1, Z.sub.2, . . . , Z.sub.q) that differ in relation to the respective process variable set are classified according to whether measures which bring about an alteration of the respective process variable (P.sub.1, P.sub.2, . . . , P.sub.m) and/or derived variable (G.sub.1, G.sub.2, . . . , G.sub.n) are necessary or recommended, wherein, in relation to each process variable set (P), at least one process state (Z.sub.1, Z.sub.2, . . . , Z.sub.q) is classified such that no measures are necessary or recommended and at least one process state (Z.sub.1, Z.sub.2, . . . , Z.sub.q) is classified such that measures are necessary or recommended, in relation to at least one process variable set, to execute the associated at least one algorithm (A.sub.1, A.sub.2, . . . , A.sub.t) and thus, taking into account the actual values (P.sub.1,actual, P.sub.2,actual, . . . , P.sub.m,actual) of the at least two process variables (P.sub.1, P.sub.2, . . . , P.sub.m) or the actual value (P.sub.1,actual, P.sub.2,actual, . . . , P.sub.m,actual) of the at least one process variable (P.sub.1, P.sub.2, . . . , P.sub.m) and the actual value (G.sub.1,actual, G.sub.2,actual, . . . , G.sub.m,actual) of the respective derived variable (G.sub.1, G.sub.2, . . . , G.sub.n) and at least one additional parameter (K.sub.1, K.sub.2, . . . , K.sub.v), to calculate which of the possible process states (Z.sub.1, Z.sub.2, . . . , Z.sub.q) that differ in relation to the respective process variable set (P) is actually present and to check whether the actually present process state (Z.sub.1, Z.sub.2, . . . , Z.sub.q) is classified as such a process state (Z.sub.1, Z.sub.2, . . . , Z.sub.q) for which a measure which brings about an alteration of the respective process variable (P.sub.1, P.sub.2, . . . , P.sub.m) and/or derived variable (G.sub.1, G.sub.2, . . . , G.sub.n) is necessary or recommended, for the case where a measure is necessary or recommended in relation to the actually present process state (Z.sub.1, Z.sub.2, . . . , Z.sub.q) because of its classification, to generate an electronic message (T) depending on the calculated process state (Z.sub.1, Z.sub.2, . . . , Z.sub.q) and to output it by means of the output device (6), wherein it is preferably provided that the electronic message (T) contains an item of information as to which of the possible process states (Z.sub.1, Z.sub.2, . . . , Z.sub.q) that differ in relation to the process variable set (P) is actually present.

21. A method for monitoring a production facility containing a moulding machine functioning in moulding cycles and optionally at least one peripheral device, wherein, by means of a computing unit, in relation to at least one process variable set of the production facility, taking into account actual values (P.sub.1,actual, P.sub.2,actual, . . . , P.sub.n,actual) of at least two process variables (P.sub.1, P.sub.2, . . . , P.sub.m) or one actual value (P.sub.1,actual, P.sub.2,actual, . . . , P.sub.n,actual) of at least one process variable (P.sub.1, P.sub.2, . . . , P.sub.m) and one actual value (G.sub.1,actual, G.sub.2,actual, . . . , G.sub.n,actual) of a respective derived variable (G.sub.1, G.sub.2, . . . , G.sub.n) and at least one additional parameter (K.sub.1, K.sub.2, K.sub.v), it is calculated which of the possible process states (Z.sub.1, Z.sub.2, . . . , Z.sub.q) of the production facility that differ in relation to the respective process variable set is actually present and it is checked whether the actually present process state (Z.sub.1, Z.sub.2, . . . , Z.sub.q) is classified as such a process state (Z.sub.1, Z.sub.2, . . . , Z.sub.q) for which a measure which brings about an alteration of the respective process variable (P.sub.1, P.sub.2, . . . , P.sub.m) and/or derived variable (G.sub.1, G.sub.2, . . . , G.sub.n) is necessary or recommended, for the case where a measure is necessary or recommended in relation to the actually present process state (Z.sub.1, Z.sub.2, . . . , Z.sub.q) because of its classification, to generate an electronic message (T) depending on the calculated process state (Z.sub.1, Z.sub.2, . . . , Z.sub.q) and to output it by means of the output device (6), wherein it is preferably provided that the electronic message (T) contains an item of information as to which of the possible process states (Z.sub.1, Z.sub.2, . . . , Z.sub.q) that differ in relation to the process variable set is actually present.

Description

[0122] Embodiment examples of the invention are discussed with reference to the figures. There are shown in:

[0123] FIG. 1 a device for monitoring a production facility containing a moulding machine functioning in moulding cycles and optionally at least one peripheral device in a schematic view,

[0124] FIG. 2 an algorithm according to a first embodiment example,

[0125] FIG. 3 an algorithm according to a second embodiment example,

[0126] FIG. 4 an algorithm according to a third embodiment example,

[0127] FIG. 5 an operator interface of the production facility.

[0128] FIG. 1 shows a production facility 1 with a computing unit 2 and a sensor 3. Two memory units 4a, 4b are arranged on a housing part of the production facility 1. A computer program product (not displayed in the representation for reasons of clarity) generates an electronic message T and sends it to an output device 6.

[0129] The output device 6 displays an electronic message T, comprising a fixed message element 8 and a variable message element 9. In a further embodiment example, the electronic message T displayed by the output device 6 can also have a different number of fixed message elements 8 and variable message elements 9 or one of these components can be dispensed with.

[0130] The form and position of the fixed message element 8 and the variable message element 9 are intrinsically as desired. However, a separate and clearly structured arrangement is particularly preferred, in order to guarantee the necessary items of information regarding the actually present process state Z.sub.l for the user at a glance in a visually appealing manner.

[0131] The output device 6 can be, for example, an operator interface (HMI) of the production facility 1, via which the items of information regarding the actually present process state Z.sub.l are visualized.

[0132] The variable message element 9 can contain, for example, actual values P.sub.1,actual, P.sub.2,actual, . . . , P.sub.m,actual of the process variables P.sub.1, P.sub.2, . . . , P.sub.m and/or actual values G.sub.1,actual, G.sub.2,actual, . . . , G.sub.n,actual of the derived variables G.sub.1, G.sub.2, . . . , G.sub.n.

[0133] FIG. 2 shows an algorithm A (represented here by way of example as a decision tree; this is not to be understood as limiting, it applies to all embodiment examples) in relation to the injection cylinder temperature of a plasticizing unit of a moulding machine formed as a plastic injection-moulding machine, wherein plastic granules are melted in the plasticizing unit.

[0134] The embodiment example comprises two process variables P.sub.1, P.sub.2, which represent the temperature T and the heating power P of a heating device of the plasticizing unit. Furthermore, T.sub.target,k represents a target value P.sub.1,target of the associated process variable P.sub.1. T.sub.actual,k and P.sub.actual,k represent two actual values of the associated process variables P.sub.1 and P.sub.2 respectively.

[0135] A tolerance range of the process variable P.sub.1 is given by the limit value for an admissible temperature deviation T. Two additional parameters K.sub.11, K.sub.12 comprise a relative index T.sub.1 of the first moulding cycle for an observation window and a limit value T.sub.2 for a counter.

[0136] The process variable set P (not represented for reasons of clarity) is formed by the two process variables P.sub.1, P.sub.2.

[0137] In the present case, nine different process states Z.sub.1, Z.sub.2, Z.sub.3, Z.sub.4, Z.sub.5, Z.sub.6, Z.sub.7, Z.sub.8, Z.sub.9 are possible.

[0138] In general, a process state Z.sub.1, Z.sub.2, . . . , Z.sub.q need not be assigned to every process variable P.sub.1, P.sub.2, . . . , P.sub.m and/or derived variable G.sub.1, G.sub.2, . . . , G.sub.n.

[0139] The actually present process state Z.sub.l is determined by execution of the algorithm A.sub.s and prepared, together with an associated hypothesis H.sub.r (not represented for reasons of clarity), in an electronic message T (not represented for reasons of clarity).

[0140] The statements below regarding the electronic message T apply to all embodiment examples.

[0141] The electronic message T can additionally comprise, on the basis of the hypotheses H.sub.r, details such as potential explanations for a process state Z.sub.1, Z.sub.2, . . . , Z.sub.q and instructions for the operator. This guarantees an assessment of the quality of the process setting, of the process state Z.sub.1, Z.sub.2, . . . , Z.sub.q, of material states (for example change in the supplied material), of influences of unmeasured disturbance variables (for example ambient air, draughts, etc.) as well as of states of elements of the production facility, such as for example a problem closing the non-return valve.

[0142] Regarding the actually present process state Z.sub.l, graphs such as for example the temporal progression (shot-dependent and/or time-dependent) of selected process variables P.sub.1, P.sub.2, . . . , P.sub.m and/or any desired parameter can also be visualized.

[0143] Furthermore, the electronic message T can be displayed in conjunction with images (for example of production facility components on which there is a problem) or acoustic notifications in the form of spoken text, audible warnings and/or music. Optical notifications in the form of warning lights and/or light projections are also possible.

[0144] The electronic message T can also be presented in the form of a partially and/or fully automatic messaging of defined people, departments and/or institutions. Interventions in the production such as selection of rejects and/or interruption in production can likewise be displayed in conjunction with the electronic message T.

[0145] The electronic message T can in addition be formed on the basis of artificial intelligence and/or can learn through expert systems from big data. A guided handling recommendation for the operator is likewise possible according to the invention, wherein an expert system additionally learns from the guidance of the action to remedy errors.

[0146] A derived variable G.sub.1 is indicated by a Boolean variable b.sub.dr,r1,T,k, the value of which indicates whether a drift of the process variable P.sub.1 of the temperature T is present in the current moulding cycle, wherein an observation window of the variable T.sub.1 of the moulding cycles for the measured temperature actual value T.sub.actual,k is used for the assessment of the presence of a drift.

[0147] The auxiliary variable k relates to the cycle counter value k for the current moulding cycle.

[0148] A counter counts the number of moulding cycles k using the auxiliary variable k and the exceeding of the limit value T.sub.2 for the counter corresponds to an event E.sub.1. The type of event E.sub.1, E.sub.2, . . . , E.sub.o is in general as desired. An event E.sub.1, E.sub.2, . . . , E.sub.o can also be a start of the facility, a change in target values P.sub.1,target, P.sub.2,target, . . . , P.sub.m,target by a user, exceeding of or failure to meet a target value P.sub.1,target, P.sub.2,target, . . . , P.sub.m,target of the process variable P.sub.1, P.sub.2, . . . , P.sub.m, etc.

Process States and Associated Possible Notifications:

[0149]

TABLE-US-00001 Process The current temperature lies within the tolerance range. state Z.sub.1 Possible notifications: None The temperature in zone <5> has been stable since <1.4.2019> Process The current temperature exceeds the target value by more state Z.sub.2 than the limit value for the admissible temperature deviation. Possible notifications: The set temperature has not yet been achieved Heating zone <5>: temperature not achieved Process The current temperature fails to meet the target value state Z.sub.3 by more than the limit value for the admissible temperature deviation. Possible notification: The set temperature has not yet been achieved Heating zone <5>: temperature not achieved Process The temperature has been almost constantly above the state Z.sub.4 target value by at least the value T for at least .sub.2 cycles. Nevertheless, the heater is still active (P.sub.actual, k > 0) Possible notifications: Check heater regulator setting Call service engineer Process The temperature has been almost constantly above the state Z.sub.5 target value by at least the value T for at least .sub.2 cycles. Possible notifications: The set temperature of <240 C.> is exceeded by <5 C.>. Possible cause: a high shear energy is introduced during the plasticizing, or influencing by adjacent heating zone Process The temperature has been almost constantly below the state Z.sub.6 target value by at least the value T for at least .sub.2 cycles. The heater is not heating at full power. Possible notifications: The set temperature of <240 C.> has failed to be met by <5 C.>. The facility does not use the maximum possible heating power in order to achieve the temperature target value. Please check regulator parameters or notify service department Process The temperature has been almost constantly below the state Z.sub.7 target value by at least the value T for at least .sub.2 cycles. The heater is heating at full power. Possible notifications: The set target temperature cannot be achieved, the heating power is too low Process The temperature has been almost constantly above the state Z.sub.8 target value by at least the value T for fewer than .sub.2 cycles. Possible notifications: None Temperature in zone <5> too high Process The temperature has been almost constantly below the state Z.sub.9 target value by at least the value T for fewer than .sub.2 cycles. Possible notifications: None Temperature in zone <5> too low

[0150] FIG. 3 shows an algorithm A.sub.s in relation to the monitoring of the melt cushion of a plasticizing unit of a moulding machine formed as a plastic injection-moulding machine, wherein plastic granules are melted in the plasticizing unit. The process variable P.sub.1 represents the residual melt cushion C of the melted plastic granules. C.sub.actual,K represents the actual value P.sub.1,actual of the associated process variable P.sub.1. Two derived variables G.sub.1, G.sub.2 represent the distribution of the residual melt cushion .sub.c,r1,k, and the average value of the residual melt cushion .sub.c,r1,k, which are preferably determined from the preceding moulding cycles.

[0151] Three additional parameters K.sub.11, K.sub.12, K.sub.13 represent a radius of the screw r.sub.screw, a minimum admissible residual melt cushion C.sub.min and a relative index T.sub.1 of the first moulding cycle for the observation window.

[0152] The process variable set P (not represented for reasons of clarity) is formed by the two process variables P.sub.1 and the two derived variables G.sub.1, G.sub.2.

[0153] In general, target values G.sub.1,target, G.sub.2,target, . . . , G.sub.n,target (not represented in the Figs.) and/or actual values G.sub.1,actual, G.sub.2,actual, . . . , G.sub.n,actual (not represented in the Figs.) of derived variables G.sub.1, G.sub.2, . . . , G.sub.n can also be connected with the derived variables G.sub.1, G.sub.2, . . . , G.sub.n.

[0154] The calculation with the process parameters by the execution of the algorithm A.sub.s distinguishes between three possible process states Z.sub.1, Z.sub.2, Z.sub.3 here.

Process States and Associated Possible Notifications:

[0155]

TABLE-US-00002 Process The current residual melt cushion fails to meet a state Z.sub.1 critical value. Possible notifications: Residual melt cushion too small Process The current residual melt cushion is close to the state Z.sub.2 critical value and could fail to meet it in one of the subsequent cycles. Possible notifications: Residual melt cushion too small Process The residual melt cushion is within an acceptable state Z.sub.3 range. Possible notifications: None

[0156] FIG. 4 shows an algorithm A.sub.s in relation to the ejector force of an ejector device of a moulding machine. The process variable P.sub.1 represents the ejector force F. Three derived variables G.sub.1, G.sub.2, G.sub.3 represent a relative change in the ejector force compared with a value of the last moulding cycle (F.sub.A,actual,kF.sub.A,k-1)/F.sub.A,actual,k-1, a relative change in the ejector force compared with a fixed reference value (F.sub.A,actual,kF.sub.A,ref)/F.sub.A,actual,ref and a relative change in the ejector force compared with the sliding reference value (F.sub.A,actual,kF.sub.A,actual,k-r4)/F.sub.A,actual,k-r4.

[0157] The actual value P.sub.1,actual of the associated process variables P.sub.1 is given by the measured maximum ejector force F.sub.A,actual in the respective moulding cycle k, wherein the number of cycles k represents an auxiliary variable.

[0158] The admissible relative change in the ejector force F.sub.A,rel represents the tolerance range of the derived variable G.sub.1. Three additional parameters K.sub.1, K.sub.2, K.sub.3 represent a relative index T.sub.4 of the comparison cycle, a fixed reference value for a maximum ejector force F.sub.A,ref and a sliding reference value for the maximum ejector force F.sub.A,actual,k-r4.

[0159] The process variable set P (not represented for reasons of clarity) is formed by the process variable P.sub.1 and the three derived variables G.sub.1, G.sub.2, G.sub.3.

[0160] The calculation with the process parameters by the execution of the algorithm A.sub.s distinguishes between five possible process states Z.sub.1, Z.sub.2, Z.sub.3, Z.sub.4, Z.sub.5 here. One hypothesis H.sub.1, H.sub.2, H.sub.3, H.sub.4, H.sub.5, not represented, for the diagnosis is present for each of these five possible process states of this process variable set P.

Process States and Associated Possible Notifications:

[0161]

TABLE-US-00003 Process Considerable increase in the ejector force state Z.sub.1 compared with the preceding cycle Possible notifications: The maximum value of the ejector force has increased by <30>% in comparison with the last shot. Process Considerable increase in the ejector force compared state Z.sub.2 with the reference cycle Possible notifications: The maximum value of the ejector force has increased by <30>% in comparison with the reference shot <10534>. Process Ejector force within the admissible range state Z.sub.3 Possible notifications: None Process Considerable increase in the ejector force within state Z.sub.4 the last <2500> cycles Possible notifications: The maximum value of the ejector force has increased by <30>% within the last <2500> cycles. Process Ejector force within the admissible range state Z.sub.5 Possible notifications: None

[0162] FIG. 5 schematically shows an embodiment example of an operator interface of an output device 6 for the output of electronic messages T.

[0163] The areas S.sub.1 to S.sub.4 contain electronic messages T (not represented for reasons of clarity) for the current moulding cycle in short form regarding actually present process states Z.sub.1, Z.sub.2, . . . , Z.sub.q in each case in relation to four different algorithms A.sub.1, A.sub.2, A.sub.3, A.sub.4. Different process states Z.sub.1, Z.sub.2, . . . , Z.sub.q are allocated to each of the four different algorithms A.sub.1, A.sub.2, A.sub.3, A.sub.4 (with the result that a process state Z.sub.sl would actually have to be referred to in relation to an algorithm A.sub.s, wherein only Z.sub.l is referred to in the present disclosure, however, for the sake of simplicity).

[0164] According to algorithm A.sub.s, different numbers of process states Z.sub.q can be present, with the result that q can have different values for different algorithms A.sub.1, A.sub.2, . . . , A.sub.t.

[0165] At the bottom right, a button B is shown, which makes it possible for the user to open windows for input and/or for further generation of information.

[0166] The areas S.sub.1 to S.sub.4 at the same time act as buttons for opening detailed items of information about the respective process state Z.sub.l. The detailed items of information regarding the process states Z.sub.1 and Z.sub.2 are visible by way of example in the drawing. The detailed items of information contain, in addition to the electronic messages T in short form S.sub.1, S.sub.2, a more detailed description L.sub.1, L.sub.2 as well as a progress bar, which presents the temporal progression of the non-entry or entry of the allocated state in the form of different colours.

[0167] The progress bar has a starting point, given by a starting time point or a first cycle number, and presents the temporal progression of the allocated state up to an end point, given by a current time point or a current cycle number. The occurrence of an event E.sub.1 is also marked by way of example in the progress bar.

[0168] An event E.sub.1, E.sub.2, . . . , E.sub.o can be e.g. a change in target value by the user, the input of a new target value data set by the user, an interruption in operation or the like.

[0169] The areas P1, P2 represented underneath the electronic message T in short form S.sub.2 additionally contain selection fields for the two process variables P.sub.1 and P.sub.2, with which the user can select which of the two process variables P.sub.1 and P.sub.2 a diagram is to be represented for.

[0170] The temporal progression of one of the actual values (P.sub.1,actual, P.sub.2,actual) and the allocated target value (P.sub.1,target, P.sub.2,target) is represented in the diagram. Each data point of the curve is allocated to a moulding cycle of the moulding machine.

[0171] In this example, electronic messages T are displayed regarding those four process states Z.sub.1, Z.sub.2, Z.sub.3, Z.sub.4 which have occurred at least once in the observation period (in the space of the starting time point and the current time point) or in the observation cycle range (in the space of the first cycle number and the current cycle number).

[0172] The observation range and/or the observation period can be chosen by the user. It is thus also possible to analyse historical data with respect to the process states Z.sub.1, Z.sub.2, Z.sub.3, Z.sub.4 that have occurred. The possibility of automatically updating the display after conclusion of a new moulding cycle can likewise be set by the user.

LIST OF REFERENCE NUMBERS

[0173] 1 production facility [0174] 2 computing unit [0175] 3 sensor [0176] 4a, 4b memory units [0177] 5 computer program [0178] 6 output device [0179] 8 fixed message element [0180] 9 variable message element [0181] P process variable set [0182] P.sub.1, P.sub.2, . . . , P.sub.m process variables [0183] G.sub.1, G.sub.2, . . . , G.sub.n derived variables [0184] E.sub.1, E.sub.2, . . . , E.sub.o event [0185] H.sub.1, H.sub.2, . . . , H.sub.r hypothesis [0186] T electronic message [0187] K.sub.1, K.sub.2, . . . , K.sub.v additional parameter [0188] P.sub.1,actual, P.sub.2,actual, . . . , P.sub.m,actual actual values of process variables [0189] P.sub.1,target, P.sub.2,target, . . . , P.sub.m,target target values of process variables [0190] G.sub.1,actual, G.sub.2,actual, . . . , G.sub.n,actual actual values of derived variables [0191] G.sub.1,target, G.sub.2,target, . . . , G.sub.n,target target values of derived variables [0192] P.sub.1, P.sub.2, . . . , P.sub.m tolerance ranges of process variables [0193] G.sub.1, G.sub.2, . . . , G.sub.n tolerance ranges of derived variables [0194] P.sub.1,ref, P.sub.2,ref, . . . , P.sub.m,ref reference values of process variables [0195] G.sub.1,ref, G.sub.2,ref, . . . , G.sub.n,ref reference values of derived variables [0196] Z.sub.1, Z.sub.2, . . . , Z.sub.q process states [0197] A.sub.1, A.sub.2, . . . , A.sub.t algorithms