Patent Application
20080289642
The present invention relates to a system and method of producing and packing tobacco products.
The present invention also relates to a unit for connecting the above system, and a method of identifying a work material.
More specifically, the present invention relates to a system—line—for producing and packing tobacco articles. The system comprises at least one manufacturing machine; at least one machine for packing the articles; and a communication network, to which a data-gathering computer is collected.
A production system normally comprises machines of different makes, and, for each make, different types of machines produced at different times and therefore with control and automation systems of different types and technology. As a result, no one comprehensive method exists of managing production materials or acquiring and managing production material data from the machines.
Known systems of the above type have the drawbacks of failing to acquire sufficient significant data and to effectively transfer production material information to the data-gathering computer.
Another drawback of known systems is that they fail to produce production data by which to identify, relatively easily, at least one production or packing material.
It is an object of the present invention to provide a system and method of producing and packing tobacco products, a unit for connecting the system, and a method of identifying a work material in the tobacco industry, all of which are designed to at least partly eliminate the above drawbacks, while at the same time being cheap and easy to implement.
According to the present invention, there are provided a system and method of producing and packing tobacco products, a unit for connecting the system, and a method of identifying a work material, as claimed in the attached Claims.
A non-limiting embodiment of the present invention will be described by way of example with reference to the accompanying drawings, in which:
Number 1 in
By way of a non-limiting example, the work materials used on machines 2a, 2b, 2c, 2d, 2e comprise paper for producing the cigarettes, and paper and/or aluminium for producing the outer and/or inner packages of the packets of cigarettes, which materials are normally fed to the machines in reels; and precut sheets of paper, blanks for producing the outer package of rigid cigarette packets or cartons, and/or stamps or coupons, which materials are normally fed to the machines on pallets and/or in boxes.
In the case of a work material 8 fed to the machines in reels, each identification code C of work material 8 is applied either to the reel core or to the outer layer of the reel; and, in the case of work material supplied on pallets and/or in boxes, each identification code C of work material 8 is applied to the box.
Each code C identifies the work material in the sense of containing information relating to the supplier and/or production lot of the material.
It should be pointed out that each work material 8 is first loaded onto the machine, either by an automatic loader or manually by an operator, and is only later actually used by the machine. The moment in which the newly loaded material is actually used by the machine is normally controlled automatically by the machine itself, but, on some machines, may be controlled manually by the operator.
With particular reference to
Connecting unit 10 receives and memorizes data D1 and D2 from devices 7 and 9, and substantially acts as a server to make data D1 and D2 available to computer 6.
The embodiment shown in the drawings has one connecting unit connected to all of machines 2.
In alternative embodiments, system 1 comprises the same number of connecting units 10 as machines 2, and each connecting unit 10 is associated with a respective machine 2.
A number of known computers (not shown) are optionally connected to communication network 5 to permit network access by a number of operators. In some embodiments, communication network 5 is an Ethernet type, preferably with a TCP/IP operating protocol.
In the embodiment shown, system 1 comprises two signalling devices 9: a signalling device 9a fitted to a machine 2 to automatically signal the instant material 8 starts to be used; and a signalling device 9b activated manually by an operator to signal the instant material 8 starts to be used.
In other embodiments, system 1 comprises no device 9a or 9b.
In the case of late-model automatic machines, device 9a is connected to connecting unit 10 via an operator interface 11 (Human-Machine-Interface, HMI), which normally comprises an industrial computer, and allows the operator to interact with one or more known control units (not shown) of machine/s 2.
Operator interface 11 cyclically acquires information about the operation of corresponding machines 2 from the control unit (not shown), and organizes the information into packages, each of which is sent, in use, to and when requested by connecting unit 10. In other words, the information packages are transmitted in master/slave mode, in which connecting unit 10 is the master.
In embodiments not shown, device 9a is connected directly to connecting unit 10, or is integrated in or connected to the control unit (not shown) which, in turn, is connected directly to connecting unit 10.
Device 9b comprises a button 12 which is pressed by the operator to signal the instant material 8 starts to be used.
In the
As shown in
In other embodiments not shown, optical reader 13 reads a conventional (i.e. one-dimensional) bar code C; and, in addition to or instead of optical reader 13, device 7 comprises an antenna for transmitting and/or receiving information from a transponder.
System 1 comprises a manual operating device 17, preferably comprising a button 18, by which the operator operates sensor device 7 manually.
With particular reference to
In the embodiment shown, sensor device 7 and operator interface 11 are connected to a communication network 20—more specifically, an Ethernet network (preferably with a TCP/IP operating protocol)—by a known switch device 21.
Connecting unit 10 comprises two Ethernet ports 22; two serial (in particular, RS422) ports 23; at least one digital input 24; and at least one digital output 25. Ethernet communication networks 5 and 20 are each connected to connecting unit 10 by a respective port 22; manual control device 19 is connected to connecting unit 10 by one of ports 23; and the unused port 23, input 24, and output 25 are indicated by dash lines in
A digital input 24 is necessary to connect connecting unit 10 to automatic machines allowing no access to their production data; in which case, the control system of the machine is connected directly to digital input 24 of connecting unit 10 by a signal indicating the instant material 8 starts to be used.
In other embodiments not shown, manual control device 19 is connected to switch device 21; and/or operator interface 11 is connected to connecting unit 10 by input 24; and/or sensor device 7 is connected to connecting unit 10 by input 24; and/or communication network 5 is connected to connecting unit 10 by output 25 or one of ports 23.
In other embodiments not shown, ports 22 and 23, input 24, and output 25 differ in number and type. More specifically: connecting unit 10 does not comprise the two ports 23; and/or connecting unit 10 does not comprise input 24 and output 25; and/or connecting unit 10 only comprises one port 22, as opposed to two; and/or connecting unit 10 comprises no port 22.
Connecting unit 10 comprises an intermediate memory 26 for memorizing and making available to computer 6 data D1 relative to at least the last two codes C of material 8 read, and data D2 relative to at least two corresponding instants at which material 8 starts to be used.
Intermediate memory 26 stores and makes the above data D1 and D2 available to computer 6 for a given time, which is longer than the time taken by computer 6 to acquire data D1 and D2 from connecting unit 10.
In actual use, connecting unit 10 preferably organizes the above data D1 and D2 in packages D, each of which comprises data D1 and D2 relative, respectively, to the code C of material 8 read, and to a corresponding instant at which material 8 starts to be used.
Connecting unit 10 also comprises a bulk memory 27 (typically, a hard disk) which cyclically memorizes the data D1 and D2 of intermediate memory 26 to prevent loss of data D1 and D2 in the event computer 6 is unable, for a prolonged period, to acquire data D1 and D2 from connecting unit 10.
Connecting unit 10 also memorizes configuration information C1 comprising, for example: information relative to the enabled ports 22, 23, inputs 24, and outputs 25, and the type and presence of machine/s 2, sensor and signalling devices 7 and 9, and manual control device 19.
Connecting unit 10 also memorizes operating parameters OP comprising, for example: the addresses of sensor device 7, the first signalling device 9 over communication network 20, and connecting unit 10 over communication networks 5 and 20; and the set-ups of machine/s 2 and sensor device 7.
Connecting unit 10 also comprises an operator interface (Human-Machine-Interface, HMI) not shown, which may comprise an operator panel connected directly to connecting unit 10, or preferably an application program resident in connecting unit 10 and remote-accessible (in known manner) by any of the computers connected to one of Ethernet communication networks 5 and 20, to allow the operator to interact with connecting unit 10.
As shown in
In the embodiment shown, device 28 laser-prints code E. In other embodiments, code E is ink-jet and/or pressure-printed by device 28.
Each code E preferably indicates in clear text or code the instant (in particular, the second-minute-hour-day-month-year) in which product P was produced, and the production system 1.
Alternatively, each code E may be integrated in an anti-imitation code with additional control characteristics.
A first operating mode will now be described with reference to a system in which the material is loaded onto the machine by an automatic loader, and the instant the material is actually used by the machine is controlled automatically by the machine itself.
At each operating cycle, sensor device 7, normally a television camera, automatically picks up code C identifying material 8, and emits a signal to transmit the relative data D1 to connecting unit 10; and signalling device 9a acquires the material-change information from the control system and makes it available to the connecting unit, which acquires data D2 relative to the instant system 1 starts to use material 8 (e.g. reel 14 and/or blanks 16). At which point, connecting unit 10 memorizes and makes data D1 and D2 available to computer 6, which may decide independently the best time to acquire data D1 and D2.
A second operating mode will now be described with reference to a system in which the material is operator-loaded manually onto the machine, and the instant the material is actually used by the machine is controlled automatically by the machine itself.
At each operating cycle, the operator positions material 8 manually with code C facing sensor device 7, and presses button 12 to operate sensor device 7, which picks up code C identifying material 8, and signals the relative data D1 to connecting unit 10; and signalling device 9a automatically signals to connecting unit 10 the data D2 relative to the instant system 1 starts to use material 8 (e.g. reel 14 and/or blanks 16). At which point, connecting unit 10 memorizes and makes data D1 and D2 available to computer 6, which may decide independently the best time to acquire data D1 and D2.
A third operating mode will now be described with reference to a system in which the material is operator-loaded manually onto the machine, and the instant the material is actually used by the machine is controlled manually by the operator.
At each operating cycle, the operator positions material 8 manually with code C facing sensor device 7, and presses button 12 to operate sensor device 7, which picks up code C identifying material 8, and signals the relative data D1 to connecting unit 10; and the operator positions material 8 ready for use by system 1. At which point, the operator presses button 18 so signalling device 9b signals to connecting unit 10 the data D2 relative to the instant system 1 starts to use material 8 (e.g. reel 14 and/or blanks 16), and connecting unit 10 memorizes and makes data D1 and D2 available to computer 6, which may decide independently the best time to acquire data D1 and D2.
Once code E is applied to product P, the material 8 used to produce product P can be identified by comparing code E and data D1 and D2 memorized in computer 6.
More specifically, when code E indicates in clear text or in code the instant product P was produced, and the production system 1, the material 8 being used at that time on system 1 need simply be determined.
System 1 and connecting unit 10 are therefore highly versatile, and provide for effectively managing a large quantity of significant information.
In this connection, it should be pointed out that connecting unit 10 safeguards against computer 6 being unable to acquire data D1 and D2, on account of being engaged in other operations.
Also worthy of note is the fact that the present invention provides for relatively easily and cheaply identifying at least one production or packing material 8 employed.
| Number | Date | Country | Kind |
|---|---|---|---|
| BO2007A 000151 | Mar 2007 | IT | national |
