EP2760748B1 - Integrated quality control of consumable materials for packaging machines - Google Patents

Description

The present invention relates to a device for using consumables on and / or with containers according to the preamble of claim 1. Such devices have long been known from the prior art. For example, labeling machines apply labels to containers or packaging machines pack individual containers or multiple containers in films, such as shrink films. Furthermore, machines are also known which provide containers with packaging, for example cardboard packaging. In these machines, a consumable material is used in each case, such as labels, shrink films, cardboard boxes and the like, which are used with or on the containers.

Such packaging machines therefore consume packaging materials in daily operation. The machine manufacturers usually specify the requirements and the quality of the consumables in the form of material specifications. On the basis of such material specifications, guarantee commitments can also be made to the customer or machine operator. However, the problem often arises that the consumables actually supplied by third parties or by suppliers do not meet the criteria that are necessary for processing the consumables. One consequence of this is that in some cases consumables have to be processed that are outside a specified tolerance range. This in turn can lead to machine malfunctions result, the cause of which, however, is often difficult to trace back to the deviating quality of the consumables.

From the DE 103 06 671 A1 a labeling machine is known which has an inspection, printing or alignment module forming an exchangeable unit. In this way, this machine can be quickly converted to different types of labels.

From the DE 20 2005 020 478 U1 a device for inspecting labels on vessels is known. In this case, however, the supplied labels are not inspected, but rather they are only inspected when they have already been arranged on the vessels, for example in order to check this correct arrangement.

From the WO 2006/010086 A2 a device according to the preamble of claim 1 is known.

The present invention is therefore based on the object of achieving a higher level of security against errors in packaging machines of this type which use the consumables mentioned.

The above-mentioned object is achieved by devices and methods according to independent claims 1 and 6. Advantageous embodiments and developments are the subject of the subclaims.

The device according to the invention according to claim 1 for using consumables on containers has a storage device which stores a supply of the consumables and a transport device which conveys the consumables to the containers. Furthermore, the device has an application unit which applies the consumable material to the containers or to combinations of containers.

According to the invention, the device has at least one sensor device which detects at least one actual value of the consumable which is characteristic of a physical property of the consumable, and a comparison device which compares the detected actual value with at least one setpoint value stored in a memory device and with a signal output device which outputs a signal as a function of a result of this comparison.

The application device can be, for example, a labeling unit which applies the labels to the containers. However, it can also be a unit which, for example, attaches shrink films or the like to the containers or to groups of containers. It would also be possible for the application unit to be a closure device which provides the containers with closures. It can also be a cartoning unit which forms cartons for the respective containers.

It is therefore proposed to introduce an integrated quality control for consumables. Said sensor device has this which determines values which are characteristic of the quality of the consumables to be processed at the moment. Consumables are understood to mean in particular those materials which, in contrast to containers, for example, are generally not recycled. These are advantageously solid materials, but application of the invention to liquid materials such as paints or adhesives would also be conceivable. The use of the consumable on and / or with containers is understood in particular to mean that a physical connection, in particular a detachable connection, is established between the consumable and the containers and / or groups of containers. This is preferably a connection which is released for the purpose of opening and / or unpacking the container.

The signal output as a function of the result can be a warning signal, for example. Furthermore, this can be a signal which causes the device to stop. Furthermore, the signal can be an indication to a user that improper material is not being used.

According to the invention, the device has a plurality of sensor devices which detect a plurality of properties of the consumable material. The results of these sensor devices are advantageously compared with setpoint values by means of comparison devices.

In a preferred embodiment, the signal output device is designed in such a way that it outputs, for example, a signal that can be perceived by a user if a deviation of the actual value from the target value is above a predetermined limit value. It however, a signal can also be output to a control device which controls the device in response to this signal.

According to the invention, tolerance limits are therefore set within which the respective actual values must lie. If such an actual value deviates, the signal is output. It would be conceivable that the signal is output when the deviation of one of the actual values from the setpoint value is above a predetermined limit value. According to the invention, logical links are also made and, for example, a signal is also output if the discrepancy between two or more actual values does not in themselves exceed the specified limit value, but there are several discrepancies.

Therefore, several actual values are determined with different sensor devices and these individual actual values are not only compared with target values, but the actual values or the respective comparison results are logically linked with one another.

According to the invention, the sensor device is arranged in the transport direction of the consumable between the storage device and the application unit. The sensor device is advantageously arranged in the transport device for the consumables close to the storage device. This close arrangement makes it possible to detect errors at an early stage and to react accordingly.

In a further advantageous embodiment, the device has a detection unit which, if a deviation of the actual value from the setpoint value is above a predetermined limit value, detects and / or outputs data which are characteristic of the occurrence of this deviation over time. For example, it is possible to record when (date and exact time) a certain error occurred. It would also be additionally possible for further data to be recorded, such as room temperature, working speed of the machine, filling level of the storage unit and the like.

In the simplest case, the storage device can be, for example, a shelf on which the supply of consumables is arranged. This system can also be the floor of a machine shop. Further possibilities for these storage units are, for example, rolls on which the material is wound and the like.

According to the invention, the device has a marking unit which, in particular, applies a marking to the consumable material if a deviation of the actual value from the target value is above a predetermined limit value. It would be possible, for example, to apply a corresponding marking to the consumable material by means of a printer, which works for example using an invisible UV ink or another visible or invisible printing medium, and this marking is preferably applied permanently.

In this way, it is also possible to identify the defective material at a later date. Furthermore, it would also be possible for the machine to additionally request the user to separate out and record a portion of the consumable material and, if necessary, to confirm by means of a signature that this material was used at a certain point in time in a certain machine. Furthermore, in a first step it would also be possible for a warning message to be issued, for example on a screen, from which it can be seen that the consumable material is outside the tolerance. The marking unit could, however, also apply other types of markings, such as, for example, punch-outs, laser markings, thermal stamps and the like.

Furthermore, it would also be conceivable that a certain proportion of the consumable material is discharged, for example a remainder of a correspondingly used label roll or also individual pieces in cardboard packaging. It would be possible, for example, for a cardboard blank whose properties are outside the limit values to be ejected. Such a cardboard blank could also be provided by the machine with an imprint, such as a stamp, from which the date of discharge can also be derived. Such a blank could also be used as evidence in later proceedings.

According to the invention, the device has a fault detection device which, when a fault occurs, outputs data characteristic of this fault. In the case of certain machine malfunctions, which, for example, do not necessarily have to lead to a standstill of the machine, it is recorded exactly when the malfunction occurred. In this way, it is possible to assign certain faults to certain consumables whose properties are outside of tolerance limits. These data can also be stored in a storage device.

In a further advantageous embodiment, the actual value, which is characteristic of the physical property, is formed from a group of physical properties that include a temperature of the consumable, a material thickness of the consumable, transparency properties of the consumable, deposits on the consumable, a number of Markings on the consumable material, a static charge on the consumable material, a geometric shape of cutouts in the consumable material, the presence of punching residues in or on the consumable material, the tolerances of blanks, combinations thereof and the like.

For example, it would be possible to provide devices (e.g. so-called sniffers) for detecting color vapors. These measurement results are advantageously evaluated online, for example in a control panel of the machine. It is possible that a measurement report can be exported for later use by the supplier.

In this way it is possible for the machine user to specify the quality of the consumables. It is also possible that a random sample check is carried out at the incoming goods department. In this way, fluctuations in the quality of the consumables can be detected online and sent to the supplier as a complaint immediately after processing. This can lead to an increase in the quality of the consumables and thus an increase in machine efficiency or, for example, a partial refund of the purchase price due to defective goods.

Furthermore, a targeted research into the causes of problems on packaging machines can also be carried out on the machine side. Precise logging makes it possible that Consumables-related errors on the machines can also be assigned to the correct cause. In this way, a reduction in quality costs can be achieved.

In a further advantageous embodiment, the sensor device detects a value that is characteristic of a length of the consumable. In particular, a value is recorded that is characteristic of a length of the material moved past the sensor device. In addition or in addition, a value can also be recorded which is characteristic of a number of the consumable items. If the consumable is, for example, a label or film roll (in which the labels follow one another, for example), a value can be recorded that is characteristic of the number of individual labels (and thus also for the length of a corresponding strip of material) .

A corresponding sensor device for detecting the length is advantageously arranged immediately after a storage device for the consumable material, for example immediately after a corresponding roll of labels or film.

In the prior art, the operator has to document a large number of production data on a production plan during production. Since the actual and the target material quantity of the suppliers can fluctuate strongly, the operator has to compare the actual number of the quantity in the box or roll with the number printed on the roll or box, note it and inform the shift supervisor about this at the supplier if necessary to be able to complain. The data must be transferred before a product change and when changing shifts.

For this purpose, the operator can use the production counter to note the amount of material used (determined on a labeling machine based on the cut labels) and compare this with the number printed on the roll. However, if the operator threads a label by hand, a few meters of crumpled film are always cut off as a result of the threading. This means that an exact actual value can no longer be determined.

In the case of a packer, the amount of material used (meters of film applied to a cardboard roll) is not determined. The production counter only determines the number of containers dispensed.

In the embodiment described above or a corresponding method, the sensor device (which is preferably arranged directly after the film roll) likewise determines the unwound length of the consumable material. In the case of labels, the number of labels can also be determined using cut marks.

Before adding new material, the operator can enter the amount of material printed on by the supplier into the machine control or scan it. The respective machine then uses the sensor device to automatically determine the deviation between the actual and setpoint values and notifies the operator of this (for example by means of a signal on the control unit of the machine or via a mobile operating unit). These data are advantageously also collected in a software tool and can then be statistically evaluated.

The present invention is further directed to a method according to claim 6 for using consumables on and / or on and / or with containers, wherein a consumable is transported starting from a storage unit to an application unit and wherein the application unit puts the consumable on or on containers or on or on combinations of containers. According to the invention, at least one actual value characteristic of a physical property of the consumable is determined or recorded by means of a sensor device and this actual value is compared with a setpoint value and a signal is output based on this comparison.

In terms of the method, it is therefore also proposed that properties of the consumable material be examined and the respective signals output as a function of these examinations.

According to the invention, the actual value is recorded during the transport of the consumable material from the storage unit to the application unit. The actual value is advantageously recorded during a movement of the consumable (in its transport direction).

The actual value is advantageously stored and particularly preferably together with information that is characteristic of its occurrence. As mentioned above, this concerns in particular temporal information or also in connection with the checked consumable material. In a further preferred method, a marking is applied to the consumable material, from which the actual value can preferably also be taken.

According to the invention, a large number of physical properties of the consumable material are recorded and the respective characteristic actual values are compared with target values.

Fig. 1

eine schematische Darstellung einer erfindungsgemäßen Vorrichtung; und

Fig. 2

ein schematisches Ablaufdiagramm für ein erfindungsgemäßes Verfahren

Further advantages and embodiments emerge from the attached drawings: They show:

Fig. 1

a schematic representation of a device according to the invention; and

Fig. 2

a schematic flow diagram for a method according to the invention

Fig. 1 shows a schematic representation of a device 1 according to the invention for using consumables 20 on and / or with containers 10. The reference numeral 2 denotes a storage unit in which the consumable 20, which can be a label tape or a shrink film, for example , is kept. Starting from this storage device 2, the consumable material 20 is conveyed by means of a transport device 4 (only shown schematically) to an application unit 6 (also only shown schematically).

Furthermore, containers 10 are also conveyed to the application unit 6 along the arrow P2. A transport device 44 for transporting the containers is therefore advantageously also provided. The application unit 6 now applies the consumable 20 to the containers. At the in Fig. 1 The embodiment shown is formed from groups of 6 containers each, which are packed into the consumable 20. The reference numeral 40 identifies the combination formed in this way from the containers 10 on the one hand and the consumable 20 on the other hand.

Reference numeral 46 denotes a transport device which in turn conveys these compilations 40 away from the application device 6. The reference symbol P3 denotes the direction in which the compilations 40 are conveyed away by the application unit 6 and the reference symbol P2 denotes the feed direction for the containers. The reference symbol P1 relates to the conveying direction of the consumable 20.

In the transport direction P1 after the storage unit 2, three sensor devices 12, 14 and 16 are provided which each detect characteristic parameters of the consumable material, as mentioned above, for example a static charge, transparency or the presence of certain markings. Correspondingly, these sensor devices 12, 14 and 16 each emit actual values I1, I2, I3, or signals which are characteristic of such actual values.

These actual values are fed to a comparison device 35, which in turn is part of a control device 30. By means of this comparison device 35, the actual values are compared with setpoint values or reference values. These setpoint values can be stored in a storage device 32.

From this comparison it can be determined whether the consumable 20 corresponds to predetermined criteria. If the actual values deviate from the target values by more than a certain amount, this can be displayed via a display device or signal output device 34 and / or a warning signal and in particular a warning signal that is physically perceptible by a user can be output to the user.

Reference numeral 36 relates to a further sensor device which detects an actual value that is independent of the consumable 20, such as an outside temperature, an outside pressure and the like.

Reference numeral 38 relates to a sensor device which determines at least one work parameter or actual work value of the application unit, for example a slip of the consumable material with respect to transport elements. It would also be possible to determine several such working parameters. These working parameters are preferably recorded together with the time of their occurrence. In this way it can be determined in the way in which deviations of the consumables from specified standards affect the operation of the application unit. These recorded working parameters can also be passed on to the control device 30. This sensor device 38 is advantageously a fault detection device which detects a fault in the application unit 6. This malfunction detection device can also record further data characteristic of the malfunction of the application unit, such as a duration of the malfunction or a duration of a standstill of the device 1.

At least one of the sensor devices advantageously detects the actual value without contact, i.e. without contact with the consumable material.

The sensor device is followed by a printing device 42 which is able to print the consumable 20. This printing device 42 is also advantageously controlled by the control device 30 and then provides the consumable 20 with an imprint if its properties deviate from the required properties.

However, other marking units would also be conceivable, such as punching units. The control device 30 can also have a timer so that the marking can also be carried out in connection with a time value. Furthermore, the application unit 6 can also have sensor devices which determine those parameters which are characteristic of the application process of the consumable material to the containers. These parameters are also advantageously recorded together with a time specification. In this way, a specific fault can also be assigned to a faulty consumable 20 in each case.

The reference numeral 48 denotes a first discharge device with which, if unsuitable material occurs, this consumable material can be discharged along the arrow P5. In this way, in the event of recourse claims against suppliers, evidence can later be provided that a specific error or a specific deviation from actual values compared to target values has occurred in the consumable 20. The discharge device 48 can be controlled in such a way that a remainder of a margin of the consumable material recognized as defective is discharged. For this purpose, the storage unit 2 can have a detection device for detecting a fill level of the consumables. For example, it would be conceivable to eject cardboard blanks with a margin recognized as being defective. The material discharged in each case could also be provided with a marking

If it is not possible to eject the consumable material, it would also be conceivable that a container ejector device 50 is provided (next to or instead of the first ejector device 48, which ejects such containers and / or containers that have been treated with a consumable material recognized as defective The container discharge device 50 is therefore advantageously arranged in the transport direction of the containers after the application unit 6. A further marking unit can advantageously be provided which marks the discharged containers and / or bundles in the manner shown above.

It would also be conceivable that such a container discharge device 50 interacts with the above-mentioned marking unit 42. If, for example, this marking unit 42 applies a marking to the consumable 20, this marking could be detected by a sensor device at a later point in time (for example if the consumable has already been used on the container) and the corresponding container treated with the marked consumable could be discharged. Furthermore, it would also be conceivable that such a discharge of containers 10 and / or combinations 40 of containers 10 or also discharge of consumables 20 (for example in the control device) is logged.

Fig. 2 shows a possible flow chart for a machine control according to the invention. The actual values I1, I2 and I3 are again output by the sensor devices 12, 14, 16 and these actual values are compared in the comparison device 32 with setpoint values S1, S2 and S3. At the in Fig. 2 As shown in the embodiment, the comparison is carried out to determine whether an amount difference between the actual value I1, I2, I3 and the setpoint values S1, S2, S3 is in each case smaller or larger than a maximum limit value T1, T2 or T3. If this is the case, different reactions can be triggered, such as B. the output of an error message, the storage of the error data, the marking of the material or the ejection of the material for later evidence purposes. If the individual limit values T1, T2, T3 are not exceeded, a link module can still be used 58 are checked whether here, for example, the actual values I1 and I2 deviate more than by the two limit values T1 'and T2' (which are in particular smaller than the values T1 and T2). If both are the case, the above-mentioned measures can be initiated again.

List of reference symbols

2

Storage unit

4th

Transport device

6th

Application device

10

Containers

12, 14, 16

Sensor devices

20th

Consumables

30th

Control device

32

Storage facility

34

Display device

35

Comparison facility

36, 38

Sensor device

40

Compilation

42

Printing device, marking unit

44

Transport device

46

Transport device

48

Discharge device

50

Container discharge device

58

Linking module

I1, I2, I3

Actual values

P1

Conveying direction

P2

Arrow, direction of feed

P3

direction

P5

arrow

S1, S2, S3

Target values

T1, T2, T3

Limit values

T1 ', T2'

Limit values

Claims (7)

1. Apparatus (1) for the application of consumable materials (20) to containers (10) with a storage device (2) which is designed in such a way that it stores a stock of the consumable material (20), with a conveying device (4) which is designed to convey the consumable material (20) to the containers (10), and with an application unit (6) which is designed in such a way that it applies the consumable material (20) to the containers (10) or to sets (40) of containers (10), wherein the apparatus (1) has at least one sensor device (12, 14, 16) which is designed in such a way that it detects at least one actual value (11, 12, 13) of the consumable material (20) which is characteristic of a physical property of the consumable material (20), a comparator device (35) which is designed in such a way that it compares the detected actual value (11, 12, 13) with at least one nominal value (S1, S2, S3) stored in a store device (32), and a signal output device (34) which is designed in such a way that it emits a signal in a manner dependent upon a result of this comparison, and wherein tolerance limits are set, within which the respective actual values (11, 12, 13) must lie, wherein the apparatus has a plurality of sensor devices (12, 14, 16) which are designed in such a way that they detect a number of properties of the consumable material, and the apparatus (1) has a fault detection device which is designed in such a way that it emits data characteristic of this fault in the event of a fault occurring, so that in this way it is possible for specific consumable materials (20), the properties of which are outside tolerance limits, also to have specific faults assigned to them, wherein the sensor device (12, 14, 16) is arranged between the storage device (2) and the application unit (6) in the conveying direction of the consumable material (20), characterised in that the fault detection device is designed in such a way that, in the event of specific faults of the machine which for example need not necessarily lead to a stoppage of the machine, it makes a record of when exactly the fault occurred, wherein the apparatus has a marking unit (42) which is designed in such a way that in particular it applies a marking to the consumable material (20) if there is a deviation of the actual value (11, 12, 13) from the nominal value (S1, S2, S3) over a pre-set threshold value (T1, T2, T3), wherein the apparatus is designed in such a way that it links the actual values (11, 12, 13) of a plurality of sensor devices (12, 14, 16) with one another logically, and also it emits a signal of the deviation of two or more actual values taken individually is not over the pre-set threshold value, but there are a plurality of variations.
2. Apparatus (1) according to claim 1,
   characterised in that
   the apparatus has a marking unit (34) which is designed in such a way that it emits a signal capable of being perceived by a user if there is a deviation of the actual value (11, 12, 13) from the nominal value (S1, S2, S3) over a pre-set threshold value (T1, T2, T3).
3. Apparatus (1) according to claim 1 with a detection unit which is designed such that, if there is a deviation of the actual value from the nominal value over a pre-set threshold value (T1, T2, T3), it detects and/or emits data which are characteristic of the time of occurrence of this deviation.
4. Apparatus (1) according to at least one of the preceding claims,
   characterised in that
   the sensor device is designed in such a way that it detects a value characteristic of a length of the consumable material.
5. Apparatus (1) according to at least one of the preceding claims,
   characterised in that
   the actual value (11, 12, 13) is characteristic of a physical property which is selected from a group of physical properties which comprises a temperature of the consumable material, a material thickness of the consumable material, deposits on the consumable material, a number of markings on the consumable material, a static charge of the consumable material, a geometrical shape of a punch-out of the consumable material, the presence of punching residues in or on the material, tolerances of blanks, combinations thereof and the like.
6. Method of applying consumable materials (20) to containers (10), wherein a consumable material (20) is conveyed starting from a storage unit (2) to an application unit (6) and wherein the application unit (6) applies the consumable material (20) to containers (10) or to sets (40) of containers (10), wherein at least one actual value (11, 12, 13) which is characteristic of a physical property of the consumable material (20) is detected by means of a sensor device (12, 14, 16), and this actual value (11, 12, 13) is compared with a nominal value (S1, S2, S3) and a signal is emitted on the basis of this comparison, and wherein tolerance limits can be set within which the respective actual values (11, 12, 13) must lie, wherein a plurality of sensor devices (12, 14, 16) are provided which detect a number of properties of the consumable material, and a fault detection device is provided which emits data characteristic of this fault in the event of a fault occurring, so that in this way it is possible, in the event of specific faults of the machine which for example need not necessarily lead to a stoppage of the machine, to make a record of when exactly the fault occurred, so that in this way it is possible for specific consumable materials (20), the properties of which are outside tolerance limits, also to have specific faults assigned to them, wherein the actual value is detected during conveying of the consumable material (20) from the storage unit (2) to the application unit (6), and a marking unit (42) is provided which in particular applies a marking to the consumable material (20) if there is a deviation of the actual value (11, 12, 13) from the nominal value (S1, S2, S3) over a pre-set threshold value (T1, T2, T3), wherein the actual values (11, 12, 13) of a plurality of sensor devices (12, 14, 16) are linked to one another logically and also a signal is emitted if the deviation of two or more actual values taken individually is not over the pre-set threshold value, but there are a plurality of variations.
7. Method according to claim 6,
   characterised in that
   the actual value (11, 12, 13) is stored, advantageously with information which is characteristic of its occurrence.

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