METHOD FOR MONITORING A PRODUCTION PROCESS, METHOD FOR INDIRECTLY DEDUCING A SYSTEMATIC DEPENDENCY, METHOD FOR ADAPTING QUALITY, METHOD FOR STARTING A PRODUCTION PROCESS, METHOD FOR PRODUCING AN EXTRUSION PRODUCT AND SYSTEM FOR PRODUCING AN EXTRUSION PRODUCT

Abstract

The invention relates to various aspects in the production of extrusion products. The properties of extruded articles are dependent significantly, in addition to their formulation, also on the setting variables and in particular on the thus resulting process variables. The setting variables and in particular the process variables thus represent a state of the extrusion process characterized as fingerprint. The thus claimed invention takes into account these facts and supports the operator of a production plant to detect earlier changes in quality and to systematically counteract a deterioration in the quality.

Claims

1. Method for monitoring a production process for an extrusion product by means of a production facility, where a measured value is determined by means of a sensor; in particular, a process variable of the production process; and a measured value acquired in this manner is compared to a predefined desired value of the measured value; in particular, a process value acquired in this manner to a predefined process desired value, characterized in that a setting parameter is determined and a thus acquired setting parameter actual value of the production facility from a production of the extrusion product is compared to a predefined setting parameter desired value and any of a deviation of the setting parameter actual value from the setting parameter desired value and/or of the measured value from the desired value of the measured value is indicated.

2. Method according to claim 1, characterized in that the setting parameter desired value and/or the desired value of the measured value are defined in dependence on a production process development parameter.

3. Method for monitoring a production process for an extrusion product with a production facility, where a measured value, in particular a process value of the production process, is determined by means of a sensor, and a measured value acquired in this manner is compared to a predefined desired value of the measured value, in particular a process value acquired in this manner is compared to a predefined process desired value, a setting parameter is determined and a thus acquired setting parameter actual value of the production facility from a production of the extrusion product can be compared to a predefined setting parameter desired value, where a deviation of at least the setting parameter actual value from the setting parameter desired value and/or of the measured value from the desired value of the measured value are indicated, in particular method according to claim 1, characterized in that the setting parameter desired value and/or the desired value of the measured value for a stationary or quasi-stationary production process are defined and/or the setting parameter desired value or the desired value of the measured value are defined during the production process at a time after startup of the production process.

4. Method according to claim 1, characterized in that the setting parameter desired value and/or a deviating desired value of the measured value are defined in the form of ranges, in particular in the form of a normal range, a warning range and an alarm range, where preferably the warning range is larger than the normal range and/or preferably the alarm range is larger than the warning range.

5. Method according to claim 1, characterized in that indication of the deviation of at least the setting parameter actual value from the setting parameter desired value and/or of the measured value from the desired value of the measured value correspond to the ranges of the setting parameter desired value and/or of the desired value of the measured value, with a normal state being indicated if the setting parameter actual value and/or the measured actual value lie within the normal range, a warning state being indicated if the setting parameter actual value and/or the measured actual value lie within the warning range and outside the normal range, and an alarm state being indicated if the setting parameter actual value and/or the measured actual value lie within the alarm range and outside the warning range.

6. Method according to claim 1, characterized in that the setting parameter desired value and/or a deviating desired value of the measured value are predefined during the production process by an operator of the machine.

7. Method according to claim 1, characterized in that the setting parameter desired value and/or a deviating desired value of the measured value are predefined by a data processing and evaluation unit.

8. Method according to claim 1, characterized in that the setting parameter desired value and/or a deviating desired value of the measured value are selected using the formulation of the extrusion product.

9. Method for indirectly deriving a systematic dependence, in a production process for an extrusion product, between a measured variable, in particular a process variable, and a setting parameter of the extrusion product and a property of the extrusion product, characterized in that a property of the extrusion product is determined by means of a sensor as a first parameter of the method in-line on the manufactured extrusion product, and/or an intensity of a property of the extrusion product is determined as a first parameter of the method, a measured variable, in particular the process variable of the production process, is determined as a second parameter of the method by means of a sensor, a third parameter of the method, in particular a parameter of the production facility from the production of the extrusion product, in particular the setting parameter of the production process, is determined, a data acquisition system digitalizes and records the determined parameters, if required, the determined parameters are stored in an organized manner with reference to one another in a database, from the data stored in the database, the specific dependence between the parameters is derived systematically by means of an electronic data processing and evaluation unit which accesses the parameters by means of an algorithm and determines the systematic dependence therefrom, where the derivation comprises at least two, in particular at least 100 data sets of parameters.

10. Method according to claim 9, characterized in that an intensity of a property of the extrusion product is determined in-line.

11. Method according to claim 9, characterized in that an intensity of a property of the extrusion product is determined offline.

12. Method according to claim 9, characterized in that the systematic dependence of the parameters is determined in the form of a curve having a coefficient of determination.

13. Method according to claim 9, characterized in that the systematic dependence of the parameters is determined by a setting range which depends on the normal range and/or the warning range and/or the alarm range for the property of the extrusion product.

14. Method according to claim 9, characterized in that the systematic dependence is determined in the form of an envelope curve, also called envelope, which depends on the normal range and/or the warning range and/or the alarm range for the property of the extrusion product.

15. Method according to claim 9, characterized in that the systematic dependence between the parameters is determined heuristically.

16. Method according to claim 9, characterized in that the systematic dependence between the parameters is determined mathematically.

17. Method according to claim 9, characterized in that the systematic dependence between the parameters is determined by means of an optimization method.

18. Method according to claim 9, characterized in that the systematic dependence between the parameters is determined by means of a self-learning optimization method.

19. Method for adapting the quality of an extrusion product manufactured with a production facility, the quality being determined and adapted in-line, characterized in that an intensity of a property of the extrusion product is determined and/or a property of the extrusion product is determined in-line on the manufactured extrusion product by means of a sensor, a measured variable, in particular a process variable, of the production process is determined by means of a sensor, and a setting parameter desired value is adapted in-line by means of the determined property and the measured variable, in particular the process variable, where adaptation of the setting parameter takes place by adjustment of an actuator, where the setting parameter desired value for the determined intensity of the property and for the measured variable, in particular the process variable, is described by a systematic dependence determined with a method according to claim 9, and by adaptation of the setting parameter, the quality of the extrusion product is altered such that the intensity of a desired property is increased and/or the intensity of an undesired property is reduced.

20. Method according to claim 19, characterized in that an intensity of a property of the extrusion product is determined in-line.

21. Method according to claim 19, characterized in that an intensity of a property of the extrusion product is determined offline.

22. Method according to claim 19, characterized in that the quality of the extrusion product has a geometrical property.

23. Method according to claim 19, characterized in that the quality of the extrusion product has an optical property.

24. Method according to claim 19, characterized in that the quality of the extrusion product has a functional property.

25. Method according to claim 19, characterized in that the quality of the extrusion product is adapted in-line and corresponds to the desired quality of the extrusion product; i. e. it has no measurable disturbance variable.

26. Method according to claim 19, characterized in that the desired quality of the extrusion product is predefined manually.

27. Method according to claim 19, characterized in that the desired quality of the extrusion product is predefined automatically.

28. Method according to claim 19, characterized in that more than one measured variables as parameters of the method are determined in-line on the manufactured extrusion product and/or at the production facility by means of one or more sensors.

29. Method according to claim 19, characterized in that the setting parameter desired value in the production process for the extrusion product for influencing the quality of the extrusion product is determined by means of a suitable specific algorithm.

30. Method according to claim 19, characterized in that the setting parameter desired value in the production process for the extrusion product for influencing the quality of the extrusion product is determined by means of a suitable specific algorithm, where the algorithm uses an in-line control deviation, that is, the difference between the desired quality of the extrusion product and the determined quality of the extrusion product, as an input variable.

31. Method according to claim 19, characterized in that the setting parameter desired value in the production process for the extrusion product for influencing the quality of the extrusion product is determined by means of an optimization method.

32. Method according to claim 19, characterized in that the setting parameter desired value in the production process for the extrusion product for influencing the quality of the extrusion product is determined by means of a self-learning optimization method.

33. Method according to claim 1, characterized in that the setting parameter actual value and/or the measured value and/or a property value and/or a setting parameter desired value and/or a desired value of the measured value and/or a property desired value and/or a normal range, in particular the range of a setting parameter desired value and/or the range of a desired value of the measured value and/or of a property desired value, and/or a warning range, in particular the range of a setting parameter desired value and/or the range of a desired value of the measured value and/or of a property desired value, and/or an alarm range, in particular the range of a setting parameter desired value and/or the range of a desired value of the measured value and/or of a property desired value, are stored in a data processing and evaluation unit and/or in a database.

34. Method according to claim 1, characterized in that the setting parameter actual value and/or the measured value and/or a property value and/or a setting parameter desired value and/or a desired value of the measured value and/or a property desired value and/or a normal range, in particular the range of a setting parameter desired value and/or the range of a desired value of the measured value and/or of a property desired value, and/or a warning range, in particular the range of a setting parameter desired value and/or the range of a desired value of the measured value and/or of a property desired value, and/or an alarm range, in particular the range of a setting parameter desired value and/or the range of a desired value of the measured value and/or of a property desired value, are stored in a database, wherein an existing database is expanded continuously.

35. Method according to claim 1, characterized in that the setting parameter actual value and/or the measured value and/or a property value and/or a setting parameter desired value and/or a desired value of the measured value and/or a property desired value and/or a normal range, in particular the range of a setting parameter desired value and/or the range of a desired value of the measured value and/or of a property desired value, and/or a warning range, in particular the range of a setting parameter desired value and/or the range of a desired value of the measured value and/or of a property desired value, and/or an alarm range, in particular the range of a setting parameter desired value and/or the range of a desired value of the measured value and/or of a property desired value, are stored in a database, the database containing only data of a specific production facility for producing one extrusion product.

36. Method according to claim 1, characterized in that the setting parameter actual value and/or the measured value and/or a property value and/or a setting parameter desired value and/or a desired value of the measured value and/or a property desired value and/or a normal range, in particular the range of a setting parameter desired value and/or the range of a desired value of the measured value and/or of a property desired value, and/or a warning range, in particular the range of a setting parameter desired value and/or the range of a desired value of the measured value and/or of a property desired value, and/or an alarm range, in particular the range of a setting parameter desired value and/or the range of a desired value of the measured value and/or of a property desired value, are stored in a database, the database containing data from a plurality of production facilities for producing an extrusion product of identical kind.

37. Method according to claim 1, characterized in that the setting parameter actual value and/or the measured value and/or a property value and/or a setting parameter desired value and/or a desired value of the measured value and/or a property desired value and/or a normal range, in particular the range of a setting parameter desired value and/or the range of a desired value of the measured value and/or of a property desired value, and/or a warning range, in particular the range of a setting parameter desired value and/or the range of a desired value of the measured value and/or of a property desired value, and/or an alarm range, in particular the range of a setting parameter desired value and/or the range of a desired value of the measured value and/or of a property desired value, are stored in a database, the database containing data from a plurality of production facilities for producing an extrusion product of different kind.

38. Method according to claim 1, characterized in that the setting parameter actual value and/or the measured value and/or a property value and/or a setting parameter desired value and/or a desired value of the measured value and/or a property desired value and/or a normal range, in particular the range of a setting parameter desired value and/or the range of a desired value of the measured value and/or of a property desired value, and/or a warning range, in particular the range of a setting parameter desired value and/or the range of a desired value of the measured value and/or of a property desired value, and/or an alarm range, in particular the range of a setting parameter desired value and/or the range of a desired value of the measured value and/or of a property desired value, are stored in a database, the database containing the data of production facilities for producing an extrusion product from one producer and/or from many producers.

39. Method according to claim 1, characterized in that the setting parameter actual value and/or the measured value and/or a property value and/or a setting parameter desired value and/or a desired value of the measured value and/or a property desired value and/or a normal range, in particular the range of a setting parameter desired value and/or the range of a desired value of the measured value and/or of a property desired value, and/or a warning range, in particular the range of a setting parameter desired value and/or the range of a desired value of the measured value and/or of a property desired value, and/or an alarm range, in particular the range of a setting parameter desired value and/or the range of a desired value of the measured value and/or of a property desired value, are stored in a database, the database synchronizing the data with a site-independent storage.

40. Method for starting a production process for an extrusion product by means of a production facility, characterized in that the setting parameter desired value is predetermined according to a development of predefined setting parameter desired values in dependence on a production process development parameter.

41. (canceled)

42. Method for manufacturing an extrusion product, wherein an extruder is operated for plastification of a thermoplastic material, a method according to claim 1being performed during manufacturing.

43. Plant for manufacturing an extrusion product, the plant having an extruder for plastification of a thermoplastic material and a nozzle for the exit of the plastic, characterized in that the plant has a data processing and evaluation unit, the data processing and evaluation unit having a programming system, the programming system being adapted for performing a method according to claim 1.

44. Plant according to claim 43, characterized in that the plant has a setting parameter measurement system for determining a setting parameter of the production process.

45. Plant according to claim 43, characterized in that the plant has a measurement value measuring system for determining a measured value of the production process, in particular a process variable.

46. Plant according to claim 43, characterized in that the plant has a property measurement system for in-line determination of an intensity of an extrusion product's property.

47. Plant according to claim 43, characterized in that the plant has an actuator for in-line influencing of the quality of the extrusion product with segmented actuating zones.

Description

[0404] In the following, the invention will be explained in more detail by means of an example of embodiment with reference to the drawing wherein

[0405] FIG. 1 schematically shows a plant for manufacturing an extrusion product.

[0406] The plant 1 in FIG. 1 for manufacturing an extrusion product 8 consists, among other components (not shown) from a production facility 2, a data acquisition and evaluation unit 3, a database 4, a setting parameter measurement system 5, a process value measurement system 6 and a property measurement system 7.

[0407] Via the data connection 9, the data acquisition and evaluation unit 3 is connected with the database 4 for data exchange.

[0408] Furthermore, the data processing and evaluation unit 3 is connected with the process value measurement system 6 for data exchange via the data connection 10, with the setting parameter measurement system 5 for data exchange via the data connection 11 and for data exchange with the property measurement system 7 via the data connection 12.

[0409] The data acquisition and evaluation unit 3 is adapted for performing a method according to the first, the second, the third, the fourth, the fifth and the sixth aspect of the invention.

[0410] The production facility 2 has the setting parameters 20, 21, 22 and the process variables 30, 31, 32. It is explicitly pointed out here that the production facility 2 can also have more or less than the indicated setting parameters 20, 21, 22, and also more or less than the indicated process variables 30, 31, 32. The setting parameters 20, 21, 22 and process variables 30, 31, 32 and their number are to be understood as schematic examples.

[0411] For manufacturing the extrusion product 8 with the plant 1, in addition the process variables 40, 41, 42 are relevant the number of which is also to be understood as a schematical example. The additional process variables 40, 41, 42 are present in the environment of the production facility 2 and can be, for instance, the air temperature 40, the air humidity 41 and the air pressure 42. It is understood that the number of process variables 40, 41, 42 in the environment of the production facility 2 selected here is also to be understood as a schematic example.

[0412] The extrusion product 8 has the properties 50, 51, 52, where it is explicitly pointed out here as well that the number of properties 50, 51, 52 is to be understood as a schematic example.

[0413] The intensity of the property 50 is determined by means of the property sensor 53 which is connected to the property measurement system 7 for data exchange via the data connection 54.

[0414] The intensity of the property 51 is determined by means of the property sensor 55 which is connected to the property measurement system 7 for data exchange via the data connection 56.

[0415] The intensity of the property 52 is determined by means of the property sensor 57 which is connected to the property measurement system 7 for data exchange via the data connection 58.

[0416] If required, the property measurement system 7 controls the property sensors 53, 55, 57, supplies them with energy, digitalizes, if required, the data arriving via the data connections 54, 56, 58, determines the intensities of the properties 50, 51, 52 at a fixed point in time defined by the data acquisition and evaluation unit 3 and forwards them to the data acquisition and evaluation unit 3 via the data connection 12.

[0417] The actual value of the setting parameter 20 is determined by the selectively combined setting parameter sensor and setting parameter encoder 23 which is connected to the setting parameter measurement system 5 for data exchange via the data connection 24.

[0418] The actual value of the setting parameter 21 is determined by the selectively combined setting parameter sensor and setting parameter encoder 25 which is connected to the setting parameter measurement system 5 for data exchange via the data connection 26.

[0419] The actual value of the setting parameter 22 is determined by the selectively combined setting parameter sensor and setting parameter encoder 27 which is connected to the setting parameter measurement system 5 for data exchange via the data connection 28.

[0420] If required, the setting parameter measurement system 5 controls the selectively combined setting parameter sensors and setting parameter encoders 23, 25, 27, supplies them with energy, digitalizes, if required, the data arriving via the data connections 24, 26, 28, determines the actual values of the properties 20, 21, 22 at a fixed point in time predefined by the data acquisition and evaluation unit 3 and forwards these data to the data acquisition and evaluation unit 3 via the data connection 11.

[0421] The actual value of the process variable 30 is determined by the process variable sensor 33 which is connected to the process variable measurement system 6 for data exchange via the data connection 34.

[0422] The actual value of the process variable 31 is determined by the process variable sensor 35 which is connected to the process variable measurement system 6 for data exchange via the data connection 36.

[0423] The actual value of the process variable 32 is determined by the process variable sensor 37 which is connected to the process variable measurement system 6 for data exchange via the data connection 38.

[0424] The actual value of the process variable 40 is determined by the process variable sensor 43 which is connected to the process variable measurement system 6 for data exchange via the data connection 44.

[0425] The actual value of the process variable 41 is determined by the process variable sensor 45 which is connected to the process variable measurement system 6 for data exchange via the data connection 46.

[0426] The actual value of the process variable 42 is determined by the process variable sensor 47 which is connected to the process variable measurement system 6 for data exchange via the data connection 48.

[0427] If required, the process variable measurement system 6 controls the process variable sensors 33, 35, 37, 43, 45, 47, supplies them with energy, digitalizes, if required, the data arriving via the data connections 34, 36, 38, 44, 46, 48, determines the actual values of the process variables 30, 31, 32, 40, 41, 42 at a fixed point in time predefined by the data acquisition and evaluation unit 3 and forwards these data to the data acquisition and evaluation unit 3 via the data connection 10.

[0428] In addition to other tasks, the data acquisition and evaluation unit 3 is responsible for controlling the setting parameters 20, 21, 22 of the production facility 2 and thus for controlling manufacturing of the extrusion product 8. Among the predefined process variables 30, 31, 32, 40, 41, 42, which cannot be directly influenced in the example in FIG. 1, among others the properties 50, 51, 52 of the extrusion product 8 are to be adapted in an optimum manner

[0429] This adaptation of the properties 50, 51, 52 of the extrusion product 8 takes place by means of an adaptation of the desired values of the setting parameters 20, 21, 22 of the production facility 2 via the selectively combined setting parameter sensors and setting parameter encoders 23, 25, 27. For this purpose, the selectively combined setting parameter sensors and setting parameter encoders 23, 25, 27 are connected via the data connections 60, 61, 62, to the data acquisition and evaluation unit 3 which for this purpose carries out a method according to the fourth aspect of the invention.

LIST OF REFERENCE NUMBERS

[0430] 1 plant

[0431] 2 production facility

[0432] 3 data acquisition and evaluation unit

[0433] 4 database

[0434] 5 setting parameter measurement system

[0435] 6 process variable measurement system

[0436] 7 property measurement system

[0437] 8 extrusion product

[0438] 9 data connection

[0439] 10 data connection

[0440] 11 data connection

[0441] 12 data connection

[0442] 20 setting parameter

[0443] 21 setting parameter

[0444] 22 setting parameter

[0445] 23 setting parameter sensor and setting parameter encoder

[0446] 24 data connection

[0447] 25 setting parameter sensor and setting parameter encoder

[0448] 26 data connection

[0449] 27 setting parameter sensor and setting parameter encoder

[0450] 28 data connection

[0451] 30 process variable

[0452] 31 process variable

[0453] 32 process variable

[0454] 33 process variable sensor

[0455] 34 data connection

[0456] 35 process variable sensor

[0457] 36 data connection

[0458] 37 process variable sensor

[0459] 38 data connection

[0460] 40 process variable air temperature

[0461] 41 process variable air humidity

[0462] 42 process variable air pressure

[0463] 43 process variable sensor

[0464] 44 data connection

[0465] 45 process variable sensor

[0466] 46 data connection

[0467] 47 process variable sensor

[0468] 48 data connection

[0469] 50 property

[0470] 51 property

[0471] 52 property

[0472] 53 property sensor

[0473] 54 data connection

[0474] 55 property sensor

[0475] 56 data connection

[0476] 57 property sensor

[0477] 58 data connection

[0478] 60 data connection

[0479] 61 data connection

[0480] 62 data connection