METHOD AND DATA DETECTION DEVICE FOR PROVIDING, RETRIEVING AND USING A DATA ELEMENT IN A PROCESS FOR PRODUCING PLASTIC SHEET MATERIAL

Abstract

The invention relates to various aspects in the production and further processing of plastic sheet material, in particular a spun-bonded non-woven fabric, a melt-blown non-woven fabric, a composite non-woven fabric, a blown film, a flat film, a plastic board or a plastic panel. A core aspect in the value chain of sheet material is a method and device for providing, retrieving and using a data element for exchanging in an over-lapping step-wise manner, a plurality of different data elements for producing the end product within the value chain of the sheet material. Within the value chain, it is possible to optimize the method using said data, to improve the construction of the used machines and systems and to improve the system technology as well as method technology for producing the sheet material.

Claims

1. Method for providing, retrieving and using a data element in the value creation chain of a plastic sheet material for producing a final product, by means of a communication protocol and a data carrier for the stage overlapping exchange of a plurality of different data elements to produce the final product within the value creation chain, characterized in that the data element is used in the value creation chain in a stage overlapping way, namely, provided from a first stage by means of the communication protocol on the data carrier and retrieved from a second stage by means of the communication protocol from the data carrier and used on a machine of the second stage.

2. Method according to claim 1, characterized in that the data element has a substance property or substance properties, in particular a substance property or substance properties of a product, in particular of a starting material and/or of a semi-finished product and/or of a final product.

3. Method according to claim 1, characterized in that the data element has a product property or product properties, in particular a product property or product properties of a starting material and/or a semi-finished product and/or a final product.

4. Method according to claim 1, characterized in that the data element has a process property or process properties, in particular a production process property or production process properties, and/or a logistics process property or logistics process properties, and/or a management process property or management process properties.

5. Method according to claim 1, characterized in the data element has a market characteristic or market characteristics.

6. Method according to claim 1, characterized in that the exchange of one or more data elements is performed across locations, in particular, that the exchange of one data element is worldwide possible.

7. Method according to claim 1, characterized in that the exchange of one or more data elements is performed across parties, especially across companies.

8. Method according to claim 1, characterized in that the exchange of one or more data elements is performed using a standardized software interface.

9. Method according to claim 1, characterized in that both the first stage and the second stage can read and/or can write the data element.

10. Method according to claim 1, characterized in that the use of the data element takes place on the part of the second stage for the further-processing of that product, by which due its production or manufacturing, at the first stage, the data element has been generated and has been provided in the data memory store, wherein the second stage is arranged chronologically after the first stage.

11. Method according to claim 1, characterized that the order of the stages is not chronological, wherein the first stage like also the second stage each can be a different arbitrary and not necessarily adjacent stage in the value creation chain.

12. Method according to claim 1, characterized that the product, in particular the final product, is provided with an individual product identifier and comprises this subsequently.

13. Method according to claim 1, characterized that a production machine for plastic sheet material is provided with an individual production machine identifier and comprises this subsequently.

14. Method according to claim 1, characterized in that a further-processing machine for plastic sheet material is provided with an individual further-processing machine identifier and comprises this subsequently.

15. Method according to claim 1, characterized in that a transport vehicle for transporting the product is provided with an individual transport vehicle identifier is provided and comprises this subsequently.

16. Method according to claim 1, characterized in that the data element is displayed and/or is detected and/or is linked and/or is provided and/or is used, via a data detection device with the product and/or with the production machine and/or with the further-processing machine and/or with the transport vehicle

17. Method according to claim 1, characterized in that the product identifier and/or the production machine identifier and/or the further-processing machine identifier and/or the transport vehicle identifier is read opto-electronically and/or electromagnetically.

18. Method according to claim 1, characterized in that the data carrier is a location-independent data memory that is available crossing location and/or crossing parties, wherein the data carrier can be a crossing location and/or a crossing parties available data cloud.

19. Method according to claim 1, characterized in that the plastic sheet material is a spunbond nonwoven.

20. Method according to claim 1, characterized in that the plastic sheet material is a meltblown nonwoven.

21. Method according to claim 1, characterized in that the plastic sheet material is a composite nonwoven.

22. Method according to claim 1, characterized in that the plastic sheet material is a blown film.

23. Method according to claim 1, characterized in that the plastic sheet material is a flat film.

24. Method according to claim 1, characterized in that the plastic sheet material is a plastic plate.

25. Method according to claim 1, characterized in that the plastic sheet material is a plastic panel.

26. Method for classifying a process quality by which in the various stages comprising value creation chain of a plastic sheet material, for example a blown film web, a flat film web or a nonwoven web, for producing a final product, for example a packaging film, an agricultural film, a thermoforming film, a plastic plate or a diaper, wherein the classifying is performed due to information and/or properties of the stages and/or a raw material and/or a semi-finished product and/or the final product, in particular by means of a method according to claim 1, in such a way that for at least one information or property, preferably for several, particularly preferably for all, a good area and/or a bad area can be defined, whereby, along the stages, information and/or properties are determined and preferably authenticated by means of a mark or an identifierare transmitted and stored as data element locally or, above all, remotely in a data record via a communication protocol, namely, either as the pure information and/or property, or just as included in the good area or bad area, or both together, or depending on the stage in different way, whereby, based on the data record is performed the classifying of a process of the stage, of a process chain along several stages, the final product and/or of a manufacturer, preferably with at least one class from the classes in all levels in the area, in a certain number of classes in the good area, in certain particularly important classes in the good area.

27. Use of data provided by a method according to claim 1, for constructing a production machine or a further-processing machine or a plant, which is used in the value creation chain of plastic sheet material, in particular a spunbond nonwoven, a meltblown nonwoven, a composite nonwoven, a blown film, a flat film, a plastic plate or a plastic panel, to produce a final product.

28. Method for improving a quality of a process, in particular a production process, a logistics process or a management process, within the value creation chain of plastic sheet material, in particular within the value creation chain of a spunbond nonwoven, a meltblown nonwoven, a composite nonwoven, a blown film, a flat film, a plastic plate or a plastic panel, for producing a final product, wherein a data element retrieved and used by means of a communication protocol and a data carrier for stage crossing exchange of a variety of different data elements, characterized in that a quality of the process is described depending on information of the data element, and thus, this quality of the process is described as a function of the data element, the data element is used to improve the quality of the process, and by improving the quality of the process, the process is changed, so that a desired property, in particular a substance property, a product property, a process property or a market property, is strengthened in its manifestation/dimension and/or an undesirable property, in particular a substance property, a product property, a process property or a market property, is reduced in its manifestation/dimension.

29. Method according to claim 28, characterized in that the quality of a production process, and thus the quality of the product production is improved.

30. Method according to claim 28, characterized in that the quality of product further-processing is improved.

31. Method according to claim 28, characterized in that the quality of a process chain is improved, thus the quality of a process chain courses.

32. Method according to claim 28, characterized in that the quality of a process setting is improved.

33. Method according to claim 28, characterized in that the product quality is improved by changing a machine setting.

34. Method according to claim 28, characterized in that product quality is improved by changing a process setting.

35. Method according to claim 28, characterized in that the quality is improved by a selection of a starting substance, thus through a selection of starting materials.

36. Method according to claim 28, characterized in that the quality of the production process is improved by reducing energy consumption.

37. Method according to claim 28, characterized in that the quality of the management process is improved by analyzing one or more data elements to generate expert knowledge.

38. Method according to claim 28, characterized in that the quality of a production planning is improved.

39. Method according to claim 28, characterized in that the quality of a production control is improved.

40. Method according to claim 28, characterized in that the quality through a control of research and development activities is improved.

41. Method according to claim 28, characterized in that the quality is improved by optimizing one distribution path, especially several or all distribution paths.

42. Method according to claim 28, characterized in that the quality is improved by selecting a storage location, especially several or all storage locations.

43. Method according to claim 28, characterized in that the quality is improved by optimizing a storage.

44. The method according to claim 28, characterized in that the quality is improved by optimizing transport costs.

45. Method according to claim 28, characterized in that the quality is improved by optimizing a logistics process.

46. Method according to claim 28, characterized in that the quality is improved by optimizing management costs.

47. Method for producing a plastic sheet material, in particular a spunbond nonwoven, a meltblown nonwoven, a composite nonwoven, a blown film, a flat foil, a plastic plate or a plastic panel, wherein an extruder is operated for plasticizing a plastic, characterized in that during the producing, a method according to one of the preceding claims is carried out.

48. Electronic data detection device, for the step crossing provision, retrieval and use of a data element in the value creation chain of a plastic sheet material, in particular a spunbond nonwoven, a meltblown nonwoven, a composite nonwoven, a blown film, a flat film a plastic plate or a plastic panel, to produce a final product, by means of a communication protocol for the step crossing exchange of a plurality of different data elements for producing the final product within the value creation chain, characterized in that the data detection device has a programming for carrying out a method according to claim 1, wherein the data detection device is performed for writing a data element, for providing the data element and/or for reading a data element for retrieval of the data element, namely, in each case by means of the communication protocol.

49. Electronic data detection device according to claim 48, characterized in that the electronic data detection device is mobile, whereby it comprises a battery, a power connection or a voltage generator.

50. Electronic data detection device according to claim 48, characterized in that the electronic data detection device is installed stationary on a production machine and/or a further-processing machine and/or a transport vehicle.

51. Electronic data retrieval device according to claim 48, characterized in that the electronic data detection device is installed stationary on the semi-finished product, on the product and/or on the final product.

52. Electronic data logging apparatus according to claim 48, characterized in that a trigger is provided for transmitting and/or completing a data record.

53. Electronic data detection device according to claim 52, characterized in that the trigger has a mechanical release.

54. Electronic data detection device according to claim 52, characterized in that the trigger has an electronic release, in particular by means of an optical sensor and/or a radio-wave sensor.

55. Electronic data logging apparatus according to claim 52, characterized in that an electronic coupling member for data exchange with a machine is provided.

56. Plant for producing a plastic sheet material, in particular a spunbond nonwoven, a meltblown nonwoven, a composite nonwoven, a blown film, a flat foil, a plastic plate or a plastic panel, wherein a extruder is operated for plasticizing a plastic, characterized in that during the producing, a method according to claim 1 is carried out.

Description

[0420] FIG. 1 is a schematic representation of a value creation of sheet material,

[0421] FIG. 2 shows in a schematic representation of a local- and overlapping value creation chain system for the synchronization of goods and information flows,

[0422] FIG. 3a, 3b show schematically the transfer of information using a communication protocol, wherein the FIGS. 3a, 3b show one exemplary embodiment, which, only for the reason of a better drawing, are here shown divided in two figure parts 3a, 3b,

[0423] FIG. 4, 5 show schematically a separation or a union, as well

[0424] FIG. 6 shows schematically a sheet material.

[0425] The value creation chain 0 for sheet material (not shown) in FIG. 1 consists essentially of the value creation stages of a starting material 1, of a production machine 2, of a semi-finished product from sheet material 3, of a further-processing machine 4, of a final product 5, of a trade 6 and of an end consumer 7.

[0426] Thereby, the production machine 2 produces a semi-finished product from a starting material 1 of sheet material 3. Subsequently, the semi-finished product from sheet material 3 is transported to a further-processing machine 4, which produces from the semi-finished product of sheet material 3 a final product 5. Finally, the final product 5 is transported to the trade 6 and there purchased from the end user 7.

[0427] All value creation stages 1, 2, 3, 4, 5, 6, 7 of the value creation chain 0 can be linked for information exchange with an electronic data detection device 8. The electronic data detection device 8 may be linked with a location independent memory 9, which is adapted to store information regardless of location.

[0428] Furthermore, all value creation stages 1, 2, 3, 4, 5, 6, 7 of the value creation chain 0 can be connected with an overlapping value creation management 10. Thereby, the information exchange between the value creation stages 1, 2, 3, 4, 5, 6, 7 of the value creation chain 0 can performed directly with the overlapping value creation management 10 or indirectly via the electronic data detection device 8, wherein the electronic data detection device 8 also allows the location-independent memory 9 for the exchange information to be connected with the overlapping value creation management 10.

[0429] Furthermore, each value creation stage 1, 2, 3, 4, 5, 6, 7 of the value creation chain 0 and/or the location-independent memory 9 can, each, for the exchange of information, be connected indirectly via the electronic data detection device 8 with the research & development 11 and/or the central data analysis 12.

[0430] In particular, the electronic data detection device 8 is performed to provide, retrieve and use a data element (not shown) by means of a communication protocol (not shown).

[0431] In particular, a data element (not shown) may include material properties (not shown), product properties (not shown), process properties (not shown) and market properties (not shown), wherein the information (not shown) of a data element (not shown) can be used for the overlapping value creation chain synchronization (not shown) of a goods(not shown) and information flow (not shown).

[0432] Furthermore, the information (not shown) of a data element (not shown) can be used to optimize the overlapping value creation chain (not shown) of a quality (not shown) of a process (not shown), in particular a production process (not shown), a logistics process (not shown) or a management process (not shown) within the value creation chain 0 of plastic sheet material (not shown).

[0433] The system for synchronization of good- and evolutionary flows 20 in FIG. 2 is based essentially on a data detection device 21 and a memory 22. The data detection device 21 and the speakers 22 are so interconnected via a data detection connection 23, whether wired or wireless, that they can exchange information (not shown here) in both directions.

[0434] The data detection device 21 is performed to detect data from a wide variety of processes and/or transmit data to the processes, such asbut not finally enumerated-from or via a raw material 24, a production plant 25, an operator 26, a roll ID 27, a further-processing machine 28, a laboratory 29, an entity or process from transportation or logistics 30, a warehouse 31 or a management process 32.

[0435] In the figure, the data detection device 21 is to be understood as a logical entity. In the practice, for example, a single data detection device 21 can be performed to be capable for data exchange of several of the processes 24 to 32, but it is just as well conceivable that a data detection device 21 can communicate with only a subset thereof, for example, even only with a single process of the processes 24 to 32.

[0436] Using the example of the raw material 24, it is conceivable that the raw material carries a special marking, for example a batch of granules can carry a unique identifier, or, for example, can make a recipe recognizable, and a specialized or generally performed data detection device 21 communicates with the data carrier on the raw material 24. The data detection device 21 recognizes the identifier (not shown) of the raw material 24. Via the identifier (i.e. the ID) of the raw material 24, the data detection device 21 can generate a data element (not shown). The data element can then stored by the data detection device 21 into the memory 22.

[0437] Preferably, the memory 22 is arranged centrally, i.e. spatially remote from the decentralized processes 24 to 32, thus also removed from the respectively associated data detection devices 21.

[0438] To make possible, that the data detection device 21 can write or has any access to the memory 22, the data transmission connection 23 must, preferably, take an authentication hurdle 33. Here it is possible to fall back on common authentication possibilities used in electronic registration from the prior art.

[0439] To make possible, that the from the data detection device 21 to memory 22 transmitted information or properties or data elements are more recognizable for the operator, or from the memory 22 retrieved data can be better recognized, a data visualization- and evaluation unit 34 may be provided for the operating person.

[0440] Typically, a silo 40, a spunbond nonwoven plant 41 (here shown as an example of a plant in FIG. 3, divided into subfigures 3a/3b) and a sheet material 42 in the process chain are connected in a network, and this network communicates with a management system 46. Alternatively, the silo 40, the spunbond nonwoven plant 41 and the sheet material 42 are divided into network segments in the process chain, which in turn are connected with the management system 46.

[0441] Depending on the design, the connection can be secured. This can be done by cryptography methods. Therefore, the transfer takes place via data blocks and messages, i.e. the data are directly available to the machine control or, if required, can be generated or used or subscribed by the controller.

[0442] All data are stored chronologically via a communication protocol in a memory 49. The process properties are transmitted, for example, as OPC-UA IEC 62541/DIN EN 62541 part 8, MQTT (MQTT since 2016 an ISO standard (ISO/IEC 20922)) or AMQP (ISO/IEC 19464), alternatively as one, defined by the manufacturer of the software interface, data frame or another, selected by the applicant, message format. It is characteristic that the time information is attached to the protocol. The storage in the memory 49 is done chronologically, in addition according to the type of data. The location of data storage by the memory 49 and use in the management system 46 may be spatially separate. The distribution follows the purpose of use and the type of data.

[0443] The transfer of the data into the further steps of the process chain takes place via communication protocols, which are transferred either chronological, chronological/positional with the sheet material, the roll goods or the final product, or which can be made available by means of an unique/individual identifier from the memory 49 by means of the management system 46, locally or globally. The choice of the identifier is also directed, but not exclusively, by the nature of the process, continuous or batch/cargo process.

[0444] A feature of these communication protocols is that these are adapted on the standards of the receiving partners so that only the relevant data for the recipient is used, however, and are, in total, available for further evaluation 47 by a development department 48. The processing entity can, in addition, provide the relevant data of the desired process step to the possible recipients. The recipient makes thereof the selection.

[0445] In a special case of the transfer of a nonwoven roll from a winder to a rewinder/a confection machine are transferred in addition to the roll characteristics such as run length, width, in particular inspection data, to enable a selection of rejects or B-ware and to allow further optimization in the further-processing.

[0446] In a further parallel step, the inspection data can be used in real time in order to optimize the production setting of the spunbond plant 41. For this, the process data are analyzed in memory 49 and the results are returned to the controller of the spunbond plant 41. For this, the communication protocols have a low latency, or they have features that enable the consideration of latencies.

[0447] Finally, the memory will be provided with data of the final packaging and delivery, so that a complete record of production data, product characteristics and packaging data is present.

[0448] With that it is possible that: [0449] The supply chain can be supported to e.g. to arrange transport means; and/or [0450] by means of a communication protocol, order-relevant data are returned to an EPA system; and/or [0451] a data record can be provided on a mobile storage medium or by identifier globally (cloud or similar) to the further-processor such as the diaper production 43 (German: Diaperproduktion); (digital reel log).

[0452] After the production of a final product, this end product has its own identifier. Typically, data records for analysis and logistics processes can be determined using this identifier.

[0453] With regard to the aspect of the invention of the production plant, it is considered the following example:

[0454] Production of a spunbond nonwoven made of PP

[0455] First, a conveyance from the silo 40 is performed, and thus, a transfer of the associated raw material data to the spunbond plant 41.

[0456] Solidifying with a calender 50 and winding on a winder leads to the sheet material 42. The transfer of the finished roll to a rewinder follows, in particular with the measured inspection data (the criterion fault-free goods yes/no can be included), process data and from the process parameters calculated characteristic data. The winding cores are coded.

[0457] It follows: wrapping the sheet material in the desired confection, simultaneous marking of the B-Ware, and removing the rejects. In the rewinder the code of the used winding core is detected. This code is then sufficient to provide to the rewinder access to all relevant data from the production machine. The rewinder is for this purposes involved in the network of the production plant and thus is authenticated by means of the identifier that can be derived from the code of the winding core and can get the relevant data. The produced, finished rolls are marked by labels. On these labels, for example, a QR or bar code is the identifier of that roll.

[0458] It follows: Transfer of ready-made sheet material (roll-ware) to a diaper machine. By means of the, on the roll label applied, identifier, which is detected by a suitable reader, the data, relevant for the diaper machine, are available via a software interface. The transmitted data contains the physical properties (e.g. strength, elongation calculated) and roll characteristics, diaper production 43 to diaper 45.

[0459] Packed according to the client's specifications (brand owner or white label) included a Lot ID (i.e. batch ID). The Lot ID of a diaper identifies it and allows, by means of further evaluation 47 in the memory 49, the representation of the entire value creation chain. This ensures a particularly process-reliable pleasant use 57 of the ready-to-sell diaper 56.

[0460] With a feedback of the end customer to the diaper manufacturer 44 about a lack of quality he can achieve full traceability to the silo via the data records.

[0461] FIGS. 4 and 5 show the merging process (for example by means of a calender) or the division process (for example, using a slitter).

[0462] As shown schematically in FIG. 5, sheet material 70 can carry mainly on a front web end 71 and/or at a rear web end 72 redundant identifiers 73 . . . 79. The sheet material can then be separated, for example by means of a slitter, so that the parts produced in each case still carry identical identifiers 73 . . . 79 and thus the process upstream in the value chain still remains traceable.

[0463] Ideally, when dividing sheet material 70 with redundant identical identifiers 73 . . . 79, the process adds to the produced pieces different sub-identifier (not shown), so that from there the different destinies can be followed.

LIST OF REFERENCE NUMBERS USED

[0464] FIG. 1 [0465] 0 value creation chain [0466] 1 starting material [0467] 2 production machine [0468] 3 semi-finished products from sheet material [0469] 4 further-processing machine [0470] 5 final product [0471] 6 trade [0472] 7 end consumers [0473] 8 electronic data detection device [0474] 9 location-independent memory [0475] 10 overlapping value creation management [0476] 11 research & development [0477] 12 central data analysis [0478] FIG. 2 [0479] 20 system [0480] 21 data detection Device [0481] 22 memory [0482] 23 data detection connection [0483] 24 raw material [0484] 25 production plant [0485] 26 operator [0486] 27 roll [0487] 28 further-processing machine [0488] 29 laboratory [0489] 30 transport/logistics [0490] 31 warehouse [0491] 32 management process [0492] 33 authentication hurdle [0493] 34 data visualization and evaluation unit [0494] FIG. 3 [0495] 40 silo [0496] 41 spunbond plant [0497] 42 sheet material [0498] 43 diaper production [0499] 44 diaper manufacturer [0500] 45 diaper [0501] 46 management system [0502] 47 further evaluation [0503] 48 development department [0504] 49 memory [0505] 50 calender [0506] 56 ready-to-sell diaper [0507] 57 use of the ready-to-sell diaper [0508] FIG. 4 [0509] 60 division process [0510] 61 run-in roll [0511] 62 first further-run-in part [0512] 63 second further-run-in part [0513] FIG. 5 [0514] 65 unification process [0515] 66 run-in part [0516] 67 second run-in part [0517] 68 unites continue-run-in roll [0518] FIG. 6 [0519] 70 sheet material [0520] 71 front web end [0521] 72 rear web end [0522] 73 . . . 79 identifier