DE10357757A1 - Controlling production process for mineral wool product manufacture involves configuring pre-product with electronic component, reading out stored data to individual production line units, adapting manufacturing/control parameters in units - Google Patents

Abstract

The method involves storing manufacturing-specific data in relation to the mineral wool products being manufactured on an electronic component, configuring a pre-product of the mineral wool product with the electronic component, reading out the stored data to the individual units on the production line and adapting the manufacturing and/or control parameters set on these units depending on the data read out. An independent claim is also included for a mineral wool product.

Description

The The invention relates to a method for controlling the production process in the production of mineral wool products in a production line with several aggregates, and a mineral wool product, which means made this control method.

Mineral wool products are usually in Production lines are produced, starting from the fiberizing aggregate have several other aggregates on the mineral wool product act until it is ready for delivery. In These aggregates become the mineral wool product with binders provided, compacted, compressed, hardened, trimmed, cut to length, laminated, wound up or stacked, wrapped etc., whereby for the production of a certain product also only Part of these process steps may be required. With others In words, the number of aggregates in the production line is determined by the required process steps for the production of respective product.

Furthermore Most of the aggregates have a product-specific effect on the mineral wool product so that their Manufacturing or control parameters new from product to product are to be adjusted. So can Mineral wool insulation for example, have a different density, which by a corresponding adjustment of the degree of compaction at the corresponding Aggregate is controlled. Such a setting is required once if a completely new product is to be produced, and continues to be respectively required if alternately different from the usual Products are manufactured. While a conversion to not yet manufactured products in the Usually occurs a few times a month, there is a conversion to Production of different products according to the incoming purchase orders usually at least several times a day, often several times an hour, to even small batches of specially desired products in a row to create.

To this purpose must currently corresponding production parameters in various areas the control systems used are stored or newly entered become. Especially with complex production approaches, however, there is the Difficulty, all conceivable manufacturing capabilities in the controllers even if these are rarely used. this leads to at considerable cost, as well as too complex, hard and high Expenditure on nurturing controls for the individual units.

Further have to corresponding changes for production changes the parameter set on the processing units of the production line be made. This is done conventionally by the use of qualified Skilled workers, which act on the controls of the respective aggregates and these reprogram accordingly. Despite the high qualification of this professionals can but not completely errors be excluded and occur in practice also. Furthermore It takes a certain amount of time for the parameters to be completely up Aggregates of a production line changed and to be produced now Product adapted are. In this period, however, the line inevitably produces committee, as the continuous manufacturing process usually not interrupted becomes. Especially with frequent This adds up to significant scrap volumes, which not only for the salable Material lost, but an additional effort for the elimination require.

The Process control of the conventional Production process in the production of mineral wool products therefore requires manual intervention at each changeover the complex control routines of the respective unit in the production line, what for the reasons mentioned as is felt to be disadvantageous.

Of the The invention is therefore based on the object, an improved method to control the production process in the production of mineral wool products indicate by means of which product changes in the production line with less personal and time expenditure with improved process reliability carried out can be.

These Task is performed by a control method with the characteristics of Claim 1 solved. This includes the steps of: saving production-specific Data with regard to the mineral wool product to be produced an electronic component (chip), providing a precursor of the Mineral wool product with the electronic module, reading the data stored on the electronic module to the individual Aggregates in the production line, and adjusting the on these aggregates set production or control parameters depending on from the data read.

The invention thus provides for the first time not to introduce the information required for production changes by external manual action on the individual units in the production process, but to "deposit" the corresponding data on a precursor of the mineral wool product, so that they directly and automatically from the individual units can be retrieved Controllers of the individual units can then use this data selectively and without manual intervention to adapt the running process steps, for which purpose corresponding control patterns in the individual unit controls can be stored, so that they depend on the read data z. B. due to a stored in the control decision table or, for example, at points by simple yes / no decisions can be changed.

It becomes according to the invention thus possible the conversion processes to perform on the individual aggregates if and only if based on the data stored on the electronic module is required are, which clearly shows the time span for the conversion process reduce. Especially it is then no longer necessary that a specialist of an aggregate goes to the next, to manually carry out the changeover. This also eliminates also the risk of human error, which is traditionally in addition to considerable committee.

in this connection is the provision of electronic components as well as storage of production-specific data on it with today's means problem-free and cost-effective possible. The required programming work is both for the individual Aggregates in the production line as well as for the electronic components only once to perform, thereby the staff and time required for this clearly reduce. For the invention is only to make sure that the correctly programmed electronic component at the right time in the pre-product is introduced, with corresponding pre-programmed electronic Building blocks for each product from the product range to be produced with low logistical and spatial effort can be kept ready. Also the programming of electronic components with regard to on completely new products can be in one step outside the production line take place, d. H. an electronic data provided with corresponding data Building block can be without impairment the production process are provided, which is the effort for one Production change significantly reduced.

Furthermore allows the remaining in the mineral wool product electronic component a traceback the production process, from which e.g. in case of quality problems valuable conclusions for possibly necessary adjustment steps can be obtained. Moreover, production data, Storage entrances and exits etc. automatically detected and be booked, so that too an automated operation monitoring z. B. with connection SAP possible is.

advantageous Further developments of the invention are the subject of the dependent claims.

So can on the electronic module further product-specific and / or customized data is stored, which also after completion the production process a clear product identification and / or Assignment to a customer possible is. This facilitates the further handling of the mineral wool product, because of the logistical effort for a correct assignment in particular reduce at delivery. Therefore, incorrect deliveries can be avoided even more reliably become. Another advantage is the fact that through Reading the data content of the electronic device also after years a statement of the manufacturer and the properties mineral wool product possible is what helps, for example, in the renovation of buildings as well is, as in the recycling of disassembled mineral wool products. The corresponding logistic advantages can thus also be given to the customer be passed on.

From Another advantage is when the electronic component of the precursor is added to a winding station or a stacking device, wherein it is placed on the mineral wool product. Then you can specific requirements for the electronic module low be held, whereby it is inexpensive to provide because which may affect the electronic module Processing steps such as upsetting or heat during curing the mineral wool product has already taken place. The one at this point in the production line added electronic module can then for example, data regarding the shape of the container, z. B. single roll or large container, the associated Packaging, labeling, points in the line, storage logistics etc. for containing the corresponding mineral wool product, ensuring correct labeling as well as an automatic capture of inventory and a automatic assignment to the respective position in the warehouse even better possible is. Here, the electronic module can directly on the mineral wool product attached, inserted in the winding or stack or possibly in the Packaging z. B. with the leading end of a wrapping film be introduced together incoming.

Alternatively, it is also possible that the electronic component is already added to the precursor in the chute of the Zerfaserungsaggregats and embedded in this. Then, the data content of the electronic module for the entire manufac turing process can be used to control the individual units. The control of the production process can be in this way also in the case almost completely automate production changes. Thus, production changes can be carried out in a very short time and with particularly high process reliability.

According to one Another alternative embodiment, the electronic Building block the precursor also in the area between a chute and a curing oven be added. This can be done across from the variant with the introduction of the electronic module directly in the chute a greater process reliability for this operation achieve less technological effort, since the precursor is essentially freely accessible in this area. On the other hand, the electronic module thus relatively early in the production line, so that the Production process largely by the control method according to the invention is controllable. The electronic components are still here uncured Material of the precursor added, preferably in this be embedded. This can be done over the continuously passing precursor arranged a feed element be, which, for example, in the form of a rotating belt with protruding arms, which are in here as an intermediate product immerse this nonwoven web and with this release the run along with electronic components and then again be excavated to be equipped with new electronic components. Alternatively, it is also possible to design the feed element so that the electronic components by means of compressed air or another At a force in the soft nonwoven web be injected.

in this connection it is of further advantage when the electronic module to the individual units addressed by means of reading devices which reads out the data content of the electronic component and transmit the control of the respective aggregate. Such reading devices can be easily with the conventional controls of the units combine and allow reliable capture of stored data, so that too a conventional one Production line can be retrofitted with little effort.

there can the position of the electronic device from the reading device a cutting unit and / or a longitudinal cutting device and / or a thickness cutting device detected and from this the section be laid in such a way that he does not meets the electronic component. This has the advantage that destruction on electronic module and / or avoided on these aggregates can be. About that It goes out so with each individual end product associated electronic component avoid that conditionally due to manufacturing tolerances of one of the products erroneously could be equipped with two electronic components while the adjacent product would not carry any electronic component. Allowed here it is the control method according to the invention to make sure that respective cut is placed so that the electronic component the desired one Blank is assigned.

According to one Another aspect of the present invention is also a mineral wool product according to claim 8, which by means of the control method according to the invention is made. This is characterized by the fact that the mineral wool product equipped with an electronic component, being on the electronic building block readable production specific data and if necessary, product or customer-specific data are stored.

The mineral wool product according to the invention thus contributes an "identification element", which is a unique Product identification allows. Furthermore, this leaves also a tracing the production process, the mineral wool product with very little stored logistical effort and possibly assigned to a customer exactly can be. If product-specific data is stored it about it even after years, the manufacturer and also the material composition of the product to capture so that in particular the disposal of the mineral wool product according to the invention is simplified.

The Invention will be described below in embodiments with reference to FIG Figures of the drawing closer explained. It shows:

1 along with 2 schematically a production line for the production of mineral wool products, on which the control method according to the invention is feasible;

3 a perspective view in section of a plate-shaped mineral wool product according to the invention with embedded electronic component; and

4 a perspective view of a roll-shaped mineral wool product according to the invention with inserted in an envelope electronic component.

As shown in the 1 and 2 For example, a production line for the production of mineral wool products has a large number of individual aggregates whose parameters are selected according to the mineral wool product to be produced, and which also do not always have to be used for all products.

The essential elements of this production line are a batch plant 1 to which the raw materials for the mineral wool material supplied and in which these raw materials are suitably mixed, a downstream smelting furnace 2 for melting this raw material mixture and a feeder 3 , by means of which the melt is a fiberizing aggregate 4 is supplied.

In this fiberizing aggregate 4 are made from this melt in a conventional manner, fibers in a chute 41 on a production line 42 fall and come there to form a primary fleece. In the chute 41 In addition, a binder is usually added to the fibers.

The primary web thus formed is then passed through the production line 42 from the fiberizing aggregate 4 led out and a compression unit 5 in which it is compressed and / or compressed to a desired degree. This is followed by a laminating station 6 on, in which the still uncured precursor can be supplied on one or both main surfaces lamination. In the adjoining curing oven 7 then the binder is cured in the mineral wool product. To the hardening furnace 7 closes a cooling unit 8th on, by means of which the cured product is cooled again. Then follows a density measuring unit 9 , By means of which the bulk density of the mineral wool product thus produced is detected to detect deviations from the desired state.

This is followed by various cutting devices, by means of which the mineral wool product is brought to its desired dimensions. So is an edge cutter 10 arranged, by means of which exact longitudinal edges are made on the product. By means of a longitudinal cutting device 11 If necessary, the product is cut into individual webs. A thickness cutter 12 usually in the form of a band saw then allows to cut the product in its thickness direction, while a subsequent cutting unit 13 produces the desired length of the product. In this area, as shown in 1 also a coating device 14 provided, by means of which, for example, an impregnation can be applied to the product or otherwise an improvement of the surface is achieved. The blanks produced in this way can then be stored in an intermediate store 15 be stored to compensate for different clock speeds within the production line.

How out 2 is recognizable, sees the production line in the further course either the continuation of the production line to a winding station 16 or a stacking station 17 Depending on whether a roll felt or insulation boards are produced. The winding station 16 this is usually a film feeding device 18 assigned, by means of which in the course of the winding process and finally the wrapping film is wound around the mineral wool product. The one from the stacking station 17 formed pile is on its way to a packaging unit 19 supplied, in which the stack is usually covered by a protective film. This envelope, which is usually designed as a shrink film, is produced by means of a downstream hot air unit 20 shrunk. Several such plate stacks can then pass through a pallet feeder 21 stacked one above the other and possibly arranged on a pallet. The container thus formed can then in a Umverpackungseinrichtung 22 be provided with an outer protective cover.

Such formed containers or roll felts are then in stock 23 respectively. 24 brought, which are electronically controlled. Before entering the camp 23 and 24 is in each case an entrance control station 25 respectively. 26 intended. At the exit of the camps 23 and 24 is an exit control station 27 arranged to be detected by means of the outgoing goods.

One in the 1 and 2 not shown electronic module can be added to the product produced in this production line in various places. For example, this is already in the chute 41 possible. Alternatively, the electronic components in the area between the chute 41 and the hardening furnace 7 be added, for example, even before the compression unit 5 or in front of the laminating station 6 or immediately before the curing oven 7 , Other options for adding the electronic module include interim storage 15 , at the winding station 16 , the pile station 17 or at the pallet feeder 21 , Concrete examples of this are given below:

Embodiment 1

In this exemplary embodiment, an electronic component is present in each end product, which in the region between the chute 41 and the compression unit 5 by means of a shotgun lance device 28 is added to the primary web. The shotgun lance device 28 has for this purpose in the present embodiment, four lances, by means of which in different sections of the primary web transversely to the production direction simultaneously four electronic components are injected at predetermined intervals by means of compressed air. The electronic components are arranged in the primary web such that after separating the precursor by means of the longitudinal cutting device 11 in each of the tracks an electronic component comes to rest. The electronic components are injected into the primary fleece in such a way that they are embedded in the interior of the product. Since the exact height position of the electronic components is generally not of considerable importance, a sufficiently reliable positioning of the electronic components can be achieved by this procedure. The number of lances depends on the number of electronic components to be arranged side by side in the preliminary product.

The four through the slitter 11 produced webs of the precursor are then through the Abfängaggregat 13 provided in the storage-specified length, stacked into stacks and further processed in the conventional manner. Since in this embodiment, an electronic component must be present in each end product, the supply frequency or the supply distance for the electronic components in the addition by means of the Einschußlanzenvorrichtung 28 tuned so that this goal is achieved after the plate blank. For this, the required positions of the electronic components are precalculated by computer.

Moreover, it is also provided in the present embodiment that the electronic component by means of the reading device of the edge cutting device 10 , the longitudinal cutting device 11 , the thickness cutter 12 and / or the cutting unit 13 acting on the control of the respective cutting device, that the cutting means does not perform separation at a location where the electronic module is present. For this purpose, the position of the associated electronic module is determined by means of the reading device of the respective unit and, if necessary, an early adjustment of the cutting position within the allowable manufacturing tolerances performed to provide the electronic module as possible in a central position within the product. Thus, even gradual deviations within the continuous production process in the production line can be counteracted. The permissible deviations from the nominal size of the mineral wool product are chosen relatively narrow in plates, so that a particularly precise tracking of the position of the electronic module is appropriate here; in roll felts or pinch felts greater deviations from the nominal size are possible, so that such a variation in the positioning of the cut is easily possible. The more precisely the electronic components are inserted into the primary nonwoven before the tunnel kiln, the lower is the expense for a possible readjustment of the cutting devices.

If the precursor is also a section in the thickness direction by means of the thickness cutting device 12 is provided, two successive Einschoss lance devices are to be arranged, by means of which electronic components are introduced in different penetration depths in the precursor, so that after the separation step in each product is an electronic module.

Embodiment 2:

A mineral wool product in the form of an intermediate rafter insulation such as INTEGRA ZKF 1-035 with a thickness of 140 mm is prepared in a conventional manner with the usual aggregates in a production line. However, this mineral wool product, an electronic component is added directly in the chute during the deposition of the just prepared, provided with binder mineral wool fibers on the production line, are stored on the production-specific data for this product. The addition in the chute 41 can be done for example via aerodynamically shaped arms or trusses, which are arranged such that the electronic component does not come to rest as possible on the surface of the product, but is still covered by subsequent fibers. If in the chute 41 several tracks are produced side by side, also several arms or trusses can be provided in appropriate numbers. These arms or trusses are in this case arranged so that they do not affect the uniform deposition of the fiber stream as possible.

The Primary fleece formed on the production belt is replaced by a pendulum tray to a secondary web greater thickness filed and then fed to the United sealing unit. The control of this compression unit has a reading device for reading the data of the electronic component, and thus detects the required adjustment parameters for making this for this Product required degree of compaction, of which u. a. the thermal conductivity of the finished product is determined. The mineral wool fleece is subsequently in the curing oven hardened and a Besäumungsaggregat Supplied (edge cutting device), which based on the data read out by the electronic module desired Width of the mineral wool product detected and a corresponding Cutting done. In a subsequent cutting unit will be the desired product length read from the electronic module and a correspondingly adapted cutting step carried out. Also in the subsequent winding machine is detected, which Product is currently in the production line and a correspondingly controlled Winding process performed, as well as the appropriate serving chosen and arranged around the produced mineral wool roll.

Should now, for example, instead of the INTEGRA ZKF 1-035 with a thickness 140 mm another product, such as. B. INTEGRA ZKF 1-040 - so one another heat conducting group - and one Thickness of 220 mm are produced, so the precursor, so the primary fleece in the chute a correspondingly differently programmed electronic component added. The following aggregates in the production line and in the present example, in particular the pendulum storage device, the compression unit and the hardening furnace capture these from previous production deviating production specific data and change their parameters accordingly. There is no manual action on this the individual aggregates required.

Embodiment 3

On the electronic components explained in the embodiment 2 Products also store product and customer specific data for example in the sense of: "product INTEGRA ZKF 1-035, 140 mm; becomes at the line X at the aggregates Y packed with the settings Z delivered to the customer AAA ", which is in the production line be detected by the subsequent control devices and therefor make sure that's the right one Time the right label for the respective product is read out, prepared and donated, without this must be predetermined by manual pre-selection, and that the mineral wool products by appropriately adapted Setting the course to the right conveyor belts and to the right one Place in the camp to come to rest. For this purpose, the course in the conveyor line according to the programming on the electronic components switched to left or right or up or down, so that different Products the same distance at the same time, in any mixture one behind the other, can use, whereby the construction of separate tape sections is eliminated. Furthermore, the Mineral wool products due to automatic identifiability independent picked up by robotic grippers or the like and, for example, one If necessary, special container associated bulk container system also be associated with different products. Of the Depository can these products then due to the on the electronic component stored product identification unerringly to the respective customer to be delivered.

alternative can the electronic components in this embodiment also after the curing oven or before the winding or stacking station to the precursor of the mineral wool product with the same advantages in terms of labeling, Handling logistics, Storage logistics and customer allocation are achieved.

Embodiment 4

In In this example, the electronic components become the precursor of the mineral wool product, whether in the chute or any other Place in the production line, so added that each resulting mineral wool product with an individually assigned electronic module is provided. Every delivered container carries with it all the necessary information, providing reliable identification of the product.

Embodiment 5:

In one to the embodiment 4 alternative embodiment becomes the precursor of the mineral wool product only one each electronic module added when a conversion of the production line carried out shall be. The reading devices on the individual units then record only at the time data from an electronic component, if amendments the control parameters of the respective unit are required. In this embodiment then leads, for example the cutting unit the corresponding cutting step always after a set dimension X through, as long as from an electronic module is read in new information, according to the Shorten from this point on, always at a measure Y is to be performed. In this way, for example, a conversion of roles wound mineral wool products to mineral wool products, which be prepared in plate form and stacked in automated Way possible, in which case a switch on the further conveyor line is controlled in this way that will cut to length Pre-product a stacking unit and not further of the winding machine supplied becomes.

at a mineral wool product which according to this embodiment produced, is not traceability of the production process for each individual containers possible; for it reduced However, the effort for the provision of electronic components essential, which also the cost of the product is kept lower than in the previous example can be.

In 3 is an embodiment of a mineral wool product according to the invention 100 shown. This is designed as a plate, in which in the region of the geometric center of an electronic component 101 is embedded. The electronic component 101 was embedded by a procedure according to embodiment 1 or embodiment 2 in the precursor and is held by the cured binder in the product. The on the electronic component 101 stored data include in addition to manufacturing Technical parameters also include product-specific and customer-specific information on the basis of which, even when installed or in the course of dismantling the mineral wool slab 100 the composition of the mineral wool material as well as the manufacturer, etc. can be determined.

4 shows a further embodiment of a mineral wool product according to the invention 200 which is roll-shaped. An electronic component 201 is hereby in an envelope 202 wrapped so that it is between the outer surface of the roll and the wrapper 202 is present or held. The electronic component 201 Therefore, after removal of the sheath 202 from the mineral wool product 200 be removed.

Claims (8)

Method for controlling the production process in the production of mineral wool products in a multi-aggregate production line, comprising the steps of: - storing production-specific data with regard to the mineral wool product to be produced ( 100 ; 200 ) on an electronic component ( 101 ; 201 ), - providing a precursor of the mineral wool product with the electronic component ( 101 ; 201 ), - readout on the electronic module ( 101 ; 201 ) data stored on the individual units in the production line, and - adjusting the production or control parameters set on these units as a function of the read-out data. Method according to claim 1, characterized in that on the electronic component ( 101 ; 201 Furthermore, product-specific and / or customer-specific data are stored. Method according to Claim 1 or 2, characterized in that the electronic component ( 201 ) the precursor at a winding station ( 16 ) or a stacking device ( 17 ) is added to the mineral wool product ( 200 ) is arranged in a package if necessary. Method according to Claim 1 or 2, characterized in that the electronic component ( 101 ) the precursor in the chute ( 41 ) and embedded in this. Method according to Claim 1 or 2, characterized in that the electronic component ( 101 ) the precursor in the area between a chute ( 41 ) and a hardening furnace ( 7 ) is added. Method according to one of Claims 1 to 5, characterized in that the electronic component ( 101 ; 201 ) is addressed to the individual units by means of reading devices, which the data content of the electronic component ( 101 ; 201 ) and transmit it to the controller of the respective unit. Method according to Claim 6, characterized in that the position of the electronic component ( 101 ) of the reading device of a cutting unit ( 13 ) and / or a longitudinal cutting device ( 11 ) and / or a thickness cutting device ( 12 ) and from this the cut is placed such that it does not contain the electronic component ( 101 ) meets. Mineral wool product ( 100 ; 200 ) produced by the control method according to any one of claims 1 to 7, characterized in that the mineral wool product ( 100 ; 200 ) with an electronic component ( 101 ; 201 ), whereby on the electronic component ( 101 ; 201 ) readable production-specific data and possibly product and / or customer-specific data are stored.