Patent Application
20200401101
The invention relates to a device for monitoring a production facility with the features of the preamble of claim 1 as well as to a production facility with such a device. The invention furthermore relates to a computer program product. Finally, the invention relates to a method for monitoring a production facility containing a moulding machine functioning in moulding cycles and optionally at least one peripheral device.
DE 10 2007 013 044 B4 reveals a generic device which displays a warning signal on a display device when a threshold value is exceeded by a stability parameter.
A further generic device is also revealed by DE 10 2004 052 499 A1, which uses an algorithm which generates a message giving information about a process state when an actual parameter value exceeds the associated limit value.
A further generic device is revealed by US 2010/0295199, which improves energy consumption and/or melt quality, wherein current process parameters allocated to the melt are compared with set values. In the case of a particular deviation the machine setting parameters are adjusted in order to optimize energy consumption or to improve melt quality. The process parameters are displayed on a screen.
Within the framework of the present disclosure, the term process state in the context of a production facility is dependent on the status of the parameters which participate directly and/or indirectly in the manufacturing process and reflects the situation of the production facility with respect to at least one parameter during the manufacturing process running in moulding cycles. The term process state can relate only to the moulding machine of the production facility, only to the optionally present at least one peripheral device or to both the moulding equipment and the at least one peripheral device. Within the framework of the present disclosure, any reference to a production facility can be understood as a reference only to the moulding machine of the production facility, only to the optionally present at least one peripheral device or to both the moulding equipment and the at least one peripheral device.
The process state within the meaning of the invention comprises e.g.:
The state of the art has the disadvantage that the known algorithms for determining the process state use a limited number of parameters and do not guarantee a possibility of calculating complex relationships between process states and the associated parameters, as well as only allowing limited conclusions as to the causes of the process states.
The object of the invention is to provide a generic device, production facility and a computer program product as well as a generic monitoring method in which the problems discussed above are remedied.
This object is achieved by a device with the features of claim 1, a production facility with the features of claim 19, a computer program product with the features of claim 20 and a method with the features of claim 21. Advantageous embodiments of the invention are defined in the dependent claims.
Because, in a memory unit which is in or can be brought into data connection with the computing unit,
The generation of the required algorithms can be effected by experts at the manufacturer of the production facility using their specialist knowledge and optionally using the results of tests, simulations and/or calculations or through the use of an artificial intelligence.
In general, one process variable set (more precisely: the actual values thereof) is allocated to each moulding cycle.
The term “process variable set” is to be understood as a short term for “at least two different process variables of the production facility or at least one process variable with at least one derived variable” and need not be present as an identifiable data set. This applies to the entire disclosure.
The determination of the required actual values, optionally the at least one derived variable, and the execution of the algorithm are preferably effected in relation to one moulding cycle, particularly preferably in relation to all moulding cycles or in relation to selected moulding cycles.
The actually present process state is displayed to the user of the device, of the computer program product and of the method via the item of information of the electronical message in a form in which the user need not take into account the underlying parameters of the process variable set. The user recognizes at a glance, represented in a compact manner, which process state is actually present, without having to interpret process variables, derived variables, actual values or additional variables.
The electronic message can contain potential explanations or instructions for the user. In the generation of the instructions, the invention can also consider potential effects of a change in the process setting on relevant process parameters, such as e.g. cycle time, and primarily give those instructions which have no influence on relevant process parameters.
Furthermore, during the execution of the computer program (preferably in every moulding cycle or only in selected moulding cycles) the calculation and classification of the actually present process state as well as the generation of an electronic message regarding the classification of the at least one actually present process state are made possible.
An advantage here is that the at least one process variable set is described by the at least one algorithm such that complex relationships between the at least two different process variables of the production facility and/or the at least one process variable with at least one derived variable can be monitored and/or are brought into connection with the actual value of the respective process variable.
An electronic message can thereby be generated not only when a threshold value is exceeded, but rather the device offers the possibility of describing the process variable set through a process state and giving information about this process state.
Through the production facility with a moulding machine functioning in moulding cycles and a monitoring device, the user thus has detailed items of information regarding the process states and the associated process variables and/or derived variables.
Furthermore, items of information regarding additional parameters, actual values of the process variables and/or of the derived variables as well as events can be prepared for the user.
Because the computer program product comprises commands which, when executed by a computing unit of a production facility containing a moulding machine functioning in moulding cycles and optionally at least one peripheral device, prompt it (preferably in every moulding cycle or only in selected moulding cycles),
In relation to the monitoring method, it is provided according to the invention that, by means of a computing unit,
It is thereby made possible for the actually present process state to be determined by taking into account the actual value of the respective process variable and/or the actual value of the respective derived variable of the process variable set.
In addition, checking the classification and passing information on to the user of the device are guaranteed.
Quite generally, there is no need to assign a process state to every process variable and/or derived variable.
In an embodiment example of the invention, it is provided that the electronic message contains an item of information as to:
It is thereby made possible to inform the user, for example, how the at least one actually present process state can be acted on.
The measures relate to the at least one actually present process state and give items of information regarding the manipulation of the at least one actually present process state.
An electronic message makes it possible to visualize the data and offers a user-friendly handling of the device through the preparation of the data, as it can be recognized which process state is actually present and optionally which measures are to be taken.
The items of information from the calculation step are prepared through the visualization such that it is clearly obvious to the user which process state is present and with which measures this process state can be acted on. In an embodiment example the electronic message can be transmitted to stored addresses (e.g. email addresses).
In an embodiment example, the electronic message can bring about an automatic response to a machine control of the production facility, e.g. an automatic change in target values of process variables or an interruption in production.
In an embodiment example, the electronic message can contain at least one link, via which the user arrives at a screen page of the output device or at an input field for a target value, where it is possible to remedy a recognized problem.
In an embodiment example, the electronic message can be saved for a later tracing.
In an embodiment example, the electronic message can be transmitted to at least one other production facility and used in the at least one other production facility to pre-emptively avoid an unfavourable state.
In an embodiment example of the invention, it is provided that at least one additional parameter and/or at least one process variable and/or at least one derived variable from at least one preceding moulding cycle can be used for the execution of the at least one algorithm.
It is thereby made possible to take into account and/or prepare a temporal progression of the at least one additional parameter and/or the at least one process variable and/or the at least one derived variable.
According to this embodiment example, this temporal progression is used for the calculation of the at least one process state in order to make a more precise classification and/or diagnosis of the actually present process state possible.
In an embodiment example of the invention, it is provided that the at least one process state and/or a change in the at least one process state is displayed in the form of the electronic message.
It is thereby made possible for the user of the device to receive specific items of information regarding the at least one process state and/or regarding the change in the at least one process state.
In an embodiment example of the invention, it is provided that at least two algorithms can be used in parallel for the calculation of the actually present process state and/or the classification of the actually present process state.
It is thereby made possible on the one hand for the calculation and/or classification of the actually present process state to be more reliable because of additional items of information of the at least one further algorithm and/or on the other hand for it to be guaranteed that at least one algorithm images the process variable set in relation to the at least one actually present process state more optimally.
In an embodiment example of the invention, it is provided that, for the case where no measure is necessary or recommended in relation to the actually present process state because of its classification, the commands during the execution of the computer program by the computing unit prompt it either not to output a message or to generate an electronic message and output it by means of the output device, wherein the electronic message contains an item of information as to which of the possible process states that differ in relation to a process variable set is actually present and/or an item of information that no measure is necessary or recommended.
It is thereby made possible for the user not to be overloaded with items of information which can distract the user from handling the device.
It is also made possible to present the user of the device with a validation in the form of an electronic message which clarifies that the at least one actually present process state does not require any necessary measures on the part of the user.
In an embodiment example of the invention, it is provided that at least one additional parameter relates to an actual value of the associated process variable and/or to an actual value of the associated derived variable from at least one preceding moulding cycle of the moulding machine, wherein it is preferably provided that a historical progression of the actual value of the associated process variable and/or the actual value of the associated derived variable is calculated from a plurality of actual values of the associated process variable and/or from a plurality of actual values of the associated derived variable from a plurality of preceding moulding cycles.
It is thereby made possible for the at least one additional parameter to include items of information from preceding moulding cycles and/or to be already adapted to preceding moulding cycles.
Advantageously, at least one additional parameter is thus given, which is optimally adjusted to the moulding cycle to be considered on the basis of the items of information regarding the variables from the preceding moulding cycles.
Using the historical progression of the actual value of the associated process variable, a temporal sequence of the changes in the actual value of the associated process variable and/or derived variable is calculated.
A succession of different actual values of the associated process variable can be visualized using the items of information regarding the preceding moulding cycles.
In an embodiment example of the invention, it is provided that at least one additional parameter is selected from the list below (any desired combination is possible):
It is thereby made possible for the at least one additional parameter not to be limited to one type of parameter, but to offer information regarding different parameter types.
The geometric parameter of the production facility is generally as desired. This geometric parameter of the production facility particularly preferably relates to structural variables, such as for example the screw diameter.
In an embodiment example of the invention, it is provided that the at least one derived variable is calculated from the actual values of at least one process variable of a current moulding cycle and/or of past moulding cycles and optionally of the at least one additional parameter and/or in relation to a value relating to a drift.
The calculation of the at least one derived variable from at least one process variable also makes actual values and/or target values regarding this derived variable possible.
In an embodiment example of the invention, it is provided that the at least one derived variable is selected from the list below:
In an embodiment example of the invention, it is provided that the at least one algorithm comprises at least one hypothesis, wherein the at least one hypothesis in relation to the actually present at least one process state and/or a change in the at least one process state represents a possible diagnosis in relation to a cause of the presence of the at least one process state and/or the change in the at least one process state.
It is thereby first made possible for the at least one process state to be checked for possible causes and, through the diagnosis of the process state, for it to be recognizable on what the actually present process state is substantiated.
For example, too high a temperature of machine components can be caused by too high an ambient temperature. This item of information is provided by the at least one hypothesis.
In an embodiment example of the invention, it is provided that the possible diagnosis can be generated by the at least one hypothesis on the basis of the at least one algorithm present and at least one event and/or can be modified depending on at least one preceding moulding cycle. It is thereby made possible for the diagnosis of the at least one process state to be regarded in relation to the actually present parameters and for a detailed cause of the actually present process state to be able to be indicated.
The hypotheses which guarantee a diagnosis of the actually present process state can be balanced by at least one parameter.
The at least one hypothesis can be altered over the temporal progression of several moulding cycles and/or adapted successively to a more applicable hypothesis.
In an embodiment example of the invention, it is provided that at least one electronic message can be displayed, which presents the at least one diagnosis in the form of an electronic message and/or which displays the applicability and/or non-applicability of the at least one hypothesis and/or the at least one process state.
It is thereby made possible for the hypotheses and their correctness also to be prepared optically for the user in addition to the visualization of the at least one process state. In addition, the user is informed about the process state.
In an embodiment example of the invention, it is provided that at least two hypotheses can be used and/or displayed in parallel for the diagnosis of the actually present at least one process state and/or a change in the at least one process state.
It is thereby made possible for at least two alternatives in the diagnosis of the at least one actually present process state to be prepared for the user of the device.
Furthermore, it is advantageous that in the combination of two hypotheses a more accurate exploration of the causes of the actually present process state is guaranteed.
In an embodiment example of the invention, it is provided that the electronic message is generated by the computing unit in relation to at least one of the possible process states with at least one fixed message element and at least one variable message element, wherein it is preferably provided that the at least one variable message element contains at least one numerical value of at least one process variable and/or at least one derived variable and/or at least one additional parameter or a graphic representation of a temporal progression of at least one numerical value of at least one process variable and/or at least one derived variable and/or at least one additional parameter.
A more flexible preparation of the data is thereby made possible and the items of information are structured to a greater extent for the user.
In an embodiment example of the invention, it is provided that the electronic message contains at least one numerical value of at least one process variable and/or at least one derived variable and/or at least one additional parameter.
A more precise information preparation is thereby made possible for the user by the electronic message.
In an embodiment example of the invention, it is provided that the electronic message contains a graphic representation of a temporal progression of at least one numerical value of at least one process variable and/or at least one derived variable and/or at least one additional parameter.
A user-friendly optical preparation of at least one numerical value is thereby made possible, which makes the historical progression of the at least one numerical value visible to the user at a glance.
In an embodiment example of the invention, it is provided that the electronic message contains at least one message element in the form of
It is thereby made possible for the user of the device to be made aware of the electronic message via several sensory perceptions and to have it available displayed in an optically appealing form which presents the data prepared visually.
The term production facility is to be distinguished from the term production site, which has a plurality of production facilities in a spatially outlined area (e.g. a production hall). The invention relates to one production facility, but can of course be used in any number of production facilities.
The moulding machine is preferably an injection-moulding machine, particularly preferably a plastic injection-moulding machine.
The at least one peripheral device is preferably a handling device (e.g. robot). The computing unit and/or the memory unit can be arranged in spatial unity with the production facility, preferably in structural unity with the moulding machine and/or with the optionally present at least one peripheral device (e.g. as part of a machine control of the production facility). The computing unit and/or the memory unit can, however, additionally or alternatively be arranged spatially distant from the production facility (cloud solution) or be located in a common (for example local) network with one or more production facilities.
The output device can have a screen and/or a signal-generating device for generating and emitting acoustic or visual signals. The output device can be formed as an operator interface of the production facility.
Embodiment examples of the invention are discussed with reference to the figures. There are shown in:
The output device 6 displays an electronic message T, comprising a fixed message element 8 and a variable message element 9. In a further embodiment example, the electronic message T displayed by the output device 6 can also have a different number of fixed message elements 8 and variable message elements 9 or one of these components can be dispensed with.
The form and position of the fixed message element 8 and the variable message element 9 are intrinsically as desired. However, a separate and clearly structured arrangement is particularly preferred, in order to guarantee the necessary items of information regarding the actually present process state Zl for the user at a glance in a visually appealing manner.
The output device 6 can be, for example, an operator interface (HMI) of the production facility 1, via which the items of information regarding the actually present process state Zl are visualized.
The variable message element 9 can contain, for example, actual values P1,actual, P2,actual, . . . , Pm,actual of the process variables P1, P2, . . . , Pm and/or actual values G1,actual, G2,actual, . . . , Gn,actual of the derived variables G1, G2, . . . , Gn.
The embodiment example comprises two process variables P1, P2, which represent the temperature T′ and the heating power P′ of a heating device of the plasticizing unit. Furthermore, T′target,k represents a target value P1,target of the associated process variable P1. T′actual,k and P′actual,k represent two actual values of the associated process variables P1 and P2 respectively.
A tolerance range of the process variable ΔP1 is given by the limit value for an admissible temperature deviation ΔT′. Two additional parameters K11, K12 comprise a relative index T1 of the first moulding cycle for an observation window and a limit value T2 for a counter.
The process variable set P (not represented for reasons of clarity) is formed by the two process variables P1, P2.
In the present case, nine different process states Z1, Z2, Z3, Z4, Z5, Z6, Z7, Z8, Z9 are possible.
In general, a process state Z1, Z2, . . . , Zq need not be assigned to every process variable P1, P2, . . . , Pm and/or derived variable G1, G2, . . . , Gn.
The actually present process state Zl is determined by execution of the algorithm As and prepared, together with an associated hypothesis Hr (not represented for reasons of clarity), in an electronic message T (not represented for reasons of clarity).
The statements below regarding the electronic message T apply to all embodiment examples.
The electronic message T can additionally comprise, on the basis of the hypotheses Hr, details such as potential explanations for a process state Z1, Z2, . . . , Zq and instructions for the operator. This guarantees an assessment of the quality of the process setting, of the process state Z1, Z2, . . . , Zq, of material states (for example change in the supplied material), of influences of unmeasured disturbance variables (for example ambient air, draughts, etc.) as well as of states of elements of the production facility, such as for example a problem closing the non-return valve.
Regarding the actually present process state Zl, graphs such as for example the temporal progression (shot-dependent and/or time-dependent) of selected process variables P1, P2, . . . , Pm and/or any desired parameter can also be visualized.
Furthermore, the electronic message T can be displayed in conjunction with images (for example of production facility components on which there is a problem) or acoustic notifications in the form of spoken text, audible warnings and/or music. Optical notifications in the form of warning lights and/or light projections are also possible.
The electronic message T can also be presented in the form of a partially and/or fully automatic messaging of defined people, departments and/or institutions. Interventions in the production such as selection of rejects and/or interruption in production can likewise be displayed in conjunction with the electronic message T.
The electronic message T can in addition be formed on the basis of artificial intelligence and/or can learn through expert systems from big data. A guided handling recommendation for the operator is likewise possible according to the invention, wherein an expert system additionally learns from the guidance of the action to remedy errors.
A derived variable G1 is indicated by a Boolean variable bdr,r1,T,k, the value of which indicates whether a drift of the process variable P1 of the temperature T′ is present in the current moulding cycle, wherein an observation window of the variable T1 of the moulding cycles for the measured temperature actual value T′actual,k is used for the assessment of the presence of a drift.
The auxiliary variable k relates to the cycle counter value k for the current moulding cycle.
A counter counts the number of moulding cycles k using the auxiliary variable k and the exceeding of the limit value T2 for the counter corresponds to an event E1. The type of event E1, E2, . . . , Eo is in general as desired. An event E1, E2, . . . , Eo can also be a start of the facility, a change in target values P1,target, P2,target, . . . , Pm,target by a user, exceeding of or failure to meet a target value P1,target, P2,target, . . . , Pm,target of the process variable P1, P2, . . . , Pm, etc.
Three additional parameters K11, K12, K13 represent a radius of the screw rscrew, a minimum admissible residual melt cushion Cmin and a relative index T1 of the first moulding cycle for the observation window.
The process variable set P (not represented for reasons of clarity) is formed by the two process variables P1 and the two derived variables G1, G2.
In general, target values G1,target, G2,target, . . . , Gn,target (not represented in the Figs.) and/or actual values G1,actual, G2,actual, . . . , Gn,actual (not represented in the Figs.) of derived variables G1, G2, . . . , Gn can also be connected with the derived variables G1, G2, . . . , Gn.
The calculation with the process parameters by the execution of the algorithm As distinguishes between three possible process states Z1, Z2, Z3 here.
The actual value P1,actual of the associated process variables P1 is given by the measured maximum ejector force FA,actual in the respective moulding cycle k, wherein the number of cycles k represents an auxiliary variable.
The admissible relative change in the ejector force ΔFA,rel represents the tolerance range of the derived variable ΔG1. Three additional parameters K1, K2, K3 represent a relative index T4 of the comparison cycle, a fixed reference value for a maximum ejector force FA,ref and a sliding reference value for the maximum ejector force FA,actual,k-r4.
The process variable set P (not represented for reasons of clarity) is formed by the process variable P1 and the three derived variables G1, G2, G3.
The calculation with the process parameters by the execution of the algorithm As distinguishes between five possible process states Z1, Z2, Z3, Z4, Z5 here. One hypothesis H1, H2, H3, H4, H5, not represented, for the diagnosis is present for each of these five possible process states of this process variable set P.
The areas S1 to S4 contain electronic messages T (not represented for reasons of clarity) for the current moulding cycle in short form regarding actually present process states Z1, Z2, . . . , Zq in each case in relation to four different algorithms A1, A2, A3, A4. Different process states Z1, Z2, . . . , Zq are allocated to each of the four different algorithms A1, A2, A3, A4 (with the result that a process state Zsl would actually have to be referred to in relation to an algorithm As, wherein only Zl is referred to in the present disclosure, however, for the sake of simplicity).
According to algorithm As, different numbers of process states Zq can be present, with the result that “q” can have different values for different algorithms A1, A2, . . . , At.
At the bottom right, a button B is shown, which makes it possible for the user to open windows for input and/or for further generation of information.
The areas S1 to S4 at the same time act as buttons for opening detailed items of information about the respective process state Zl. The detailed items of information regarding the process states Z1 and Z2 are visible by way of example in the drawing. The detailed items of information contain, in addition to the electronic messages T in short form S1, S2, a more detailed description L1, L2 as well as a progress bar, which presents the temporal progression of the non-entry or entry of the allocated state in the form of different colours.
The progress bar has a starting point, given by a starting time point or a first cycle number, and presents the temporal progression of the allocated state up to an end point, given by a current time point or a current cycle number. The occurrence of an event E1 is also marked by way of example in the progress bar.
An event E1, E2, . . . , Eo can be e.g. a change in target value by the user, the input of a new target value data set by the user, an interruption in operation or the like.
The areas P1, P2 represented underneath the electronic message T in short form S2 additionally contain selection fields for the two process variables P1 and P2, with which the user can select which of the two process variables P1 and P2 a diagram is to be represented for.
The temporal progression of one of the actual values (P1,actual, P2,actual) and the allocated target value (P1,target, P2,target) is represented in the diagram. Each data point of the curve is allocated to a moulding cycle of the moulding machine.
In this example, electronic messages T are displayed regarding those four process states Z1, Z2, Z3, Z4 which have occurred at least once in the observation period (in the space of the starting time point and the current time point) or in the observation cycle range (in the space of the first cycle number and the current cycle number).
The observation range and/or the observation period can be chosen by the user. It is thus also possible to analyse historical data with respect to the process states Z1, Z2, Z3, Z4 that have occurred. The possibility of automatically updating the display after conclusion of a new moulding cycle can likewise be set by the user.
| Number | Date | Country | Kind |
|---|---|---|---|
| A 50551/2019 | Jun 2019 | AT | national |
