Method for controlling the operation of a production line and production line suitable therefor
In order to be able to achieve a control target (Z) selected by a user in the simplest possible way during operation of a production line ( 500 ), performance indicators (LKs) are calculated from performance parameters (LP) which are measurable or discernible or can be specified and can originate from several different machines ( 100, 200, 300 ) of the production line ( 500 ). By achieving or even optimizing these one or more performance indicators (LKs) stored in a control with control target (Z) within their target range, it is ensured that the overall regulation target (Z), i.e. for the entire production line ( 500 ), is also achieved.
1. A method for regulating operation of a production line including:
a single-track or multi-track slicing machine in which product calibers are cut into slices and the slices are grouped into portions,
a packaging machine for packaging the portions, with a feeder station in which a portion of the portions can be deposited on or in a packaging element,
a transport and buffer machine, hereinafter TP machine, for transporting the portions from the slicing machine to the feeder station of the packaging machine and buffering in-between, and
a line control for controlling moveable parts of the production line,
wherein performance indicators are calculated for the production line from performance parameters which are selectable or fixed,
wherein a selection of control targets is specified, for achievement of which a target value or a target range of at least one of the performance indicators is correlated,
wherein the method comprises:
receiving a control target selected by a user, and
automatically controlling those selectable performance parameters which are required to determine the at least one performance indicator correlated with the selected control target in such a way that the target value of the correlated at least one performance indicator required for the selected control target is achieved or the target range of the correlated at least one performance indicator is achieved;
wherein a first performance indicator LK 1 reflecting a number of portions packaged per unit time is calculated using the following performance parameters:
AnzP=number of portions that can be produced from a product caliber K,
U/s=rotational speed of a blade of the slicing machine,
T/s=number of cycles of the packaging machine,
AnzR=number of rows of portions running in transverse direction to a passage direction, which comprises a format fed at once at a feeding point,
Lt=loading time of the slicing machine,
AnzS=number of slices per portion,
AnzL=number of blank cuts of the slicing machine between two successively produced portions.
2. The method according to claim 1 , further comprising
receiving, from the user, specification of one or more of the selectable performance parameters with regard to target value or target range,
and/or
receiving, from the user, specification of a target value or target range for a performance parameter which can be monitored by sensors of the production line and which represents a quality criterion.
3. The method according to claim 1 , wherein
a performance indicator of the performance indicators contains performance parameters from different machines
and/or
a permissible range is specified for the selectable performance parameters.
4. The method according to claim 1 , wherein
an automatically controlled performance parameter, which is used to calculate a performance indicator for which a target range is predetermined, is controlled in such a way that the performance indicator calculated with it is optimized within this target range,
and/or
the at least one performance indicator correlated with the selected control target is monitored as a regulation target during operation of the production line and the selectable performance parameters associated with the at least one performance indicator are automatically readjusted during operation of the production line in such a way that during operation of the production line the necessary target value of the correlated at least one performance indicator is permanently achieved or the target range of the at least one performance indicator is achieved.
5. The method according to claim 1 , wherein
the calculation of a performance indicator can be carried out with aid of a machine control of one of the slicing machine, the packaging machine, or the transport and buffer machine, and
the line control is superordinate to the machine controls by executing a simulation on the machine control or the line control or an external control.
6. The method of claim 1 , wherein the first performance indicator LK 1 is calculated using the following formula:
LK
1
=
(
AnzP
×
U
/
s
)
/
[
T
/
s
×
AnzR
×
(
Lt
×
U
/
s
+
AnzP
×
(
AnzS
+
AnzL
)
)
]
.
7. The method according to claim 1 , wherein for a first control target or regulation target of a maximum number of portions packaged by the production line per unit of time
the performance parameters correlated with the first performance indicator LK 1 are controlled in such a way that LK 1 >1.
8. The method according to claim 7 , wherein the performance parameters correlated with the first performance indicator LK 1 are controlled in such a way that LK 1 is in a range from 1.03 to 1.15.
9. The method according to claim 1 , wherein, for a second control target or regulation target of a cycle operation of the packaging machine with a highest cycle time that is at most 10% above a lowest cycle time,
the performance parameters correlated with the first performance indicator LK 1 are controlled in such a way that LK 1 >1,
and/or
the performance parameters correlated with a second performance indicator LK 2 are controlled in such a way that LK 2 >1.
10. The method according to claim 1 , wherein, for a second control target or regulation target of a cycle operation of the packaging machine with a highest cycle time at most 5% above a lowest cycle time,
the performance parameters correlated with the first performance indicator LK 1 are controlled in such a way that LK 1 is in a range from 1.03 to 1.15, each included,
and/or
the performance parameters correlated with a second performance indicator LK 2 are controlled in such a way that LK 2 is in a range from 1.05 to 1.20, each included.
11. The method according to claim 1 , wherein a second performance indicator LK 2 reflecting a sufficient buffering capacity of the TP machine is calculated using the following performance parameters:
Pt=time that the packaging machine can be operated from a time the slicing machine stops using buffered portions,
Wt=refill time comprising loading time Lt of the slicing machine plus transport time Tt of a first portion after restarting the slicing machine from the slicing machine to a feeding point of the packaging machine.
12. The method according to claim 11 , wherein the second performance indicator LK 2 is calculated according to the following formula:
LK
2
=
Pt
/
Wt
.
13. The method according to claim 12 , further comprising receiving, from the user, a specific target value or a maximum target value for a freely selectable performance parameter.
14. The method according to claim 1 , wherein
when the target value or target range of a performance indicator correlated with a control target or regulation target is achieved at a plurality of operating points, at least one secondary performance parameter is stored for each of the individual operating points, which is not included in the calculation of the performance indicator,
this secondary performance parameter is additionally selectable by the user as a secondary optimization target.
15. A production line for producing and packaging of portions each including one or more slices cut from a product caliber, comprising:
a packaging machine with a feeder station in which a portion can be deposited on or in a packaging element;
a single-track or multi-track slicing machine for separating slices from a product caliber, including a discharge unit for the slices;
a transport and buffer machine in-between the slicing machine and the packaging machine for transporting and buffering the portions; and
a control unit;
wherein performance indicators are calculatable for the production line from performance parameters which are selectable or fixed, and a selection of control targets is specifiable, for achievement of which a target value or a target range of at least one of the performance indicators is correlatable, wherein the control unit is configured to, based on a control target selected by a user, automatically control those selectable performance parameters which are required to determine the at least one performance indicator correlated with the selected control target in such a way that the target value of the correlated at least one performance indicator required for the selected control target is achieved or the target range of the correlated at least one performance indicator is achieved, and wherein a first performance indicator LK 1 reflecting a number of portions packaged per unit time is calculatable using the following performance parameters:
AnzP=number of portions that can be produced from a product caliber K,
U/s=rotational speed of a blade of the slicing machine,
T/s=number of cycles of the packaging machine,
AnzR=number of rows of portions running in transverse direction to a passage direction, which comprises a format fed at once at a feeding point,
Lt=loading time of the slicing machine,
AnzS=number of slices per portion,
AnzL=number of blank cuts of the slicing machine between two successively produced portions.
16. The production line according to claim 15 , wherein the production line has at least one sensor connected to the control unit, wherein the at least one sensor is configured to detect a performance parameter.
17. The production line according to claim 15 , wherein
the production line comprises conveyor belts within a transport section, and
one or more of the conveyor belts within the transport section are designed in such a way that they are usable as buffer belts.
18. The production line according to claim 17 , wherein the one or more conveyor belts are equipped with controllable servo drives.
19. The production line according to claim 16 , wherein the production line comprises
a weighing belt with a scale for weighing a portion
and/or
a discharge belt for discharging a portion
and/or
a distributing belt or splaying belt for bringing portions running side by side onto a track spacing of the packaging machine and/or
a compensating belt for bringing portions running side by side in a direction of travel to a same position
and/or
a format belt for accurately positioning portions to form at least one format
and/or
a feeder belt for transferring a format onto at least one packaging means.
20. A method for regulating operation of a production line including:
a single-track or multi-track slicing machine in which product calibers are cut into slices and the slices are grouped into portions,
a packaging machine for packaging the portions, with a feeder station in which a portion of the portions can be deposited on or in a packaging element,
a transport and buffer machine, hereinafter TP machine, for transporting the portions from the slicing machine to the feeder station of the packaging machine and buffering in-between, and
a line control for controlling moveable parts of the production line,
wherein performance indicators are calculated for the production line from performance parameters which are selectable or fixed,
wherein a selection of control targets is specified, for achievement of which a target value or a target range of at least one of the performance indicators is correlated,
wherein the method comprises:
receiving a control target selected by a user, and
automatically controlling those selectable performance parameters which are required to determine the at least one performance indicator correlated with the selected control target in such a way that the target value of the correlated at least one performance indicator required for the selected control target is achieved or the target range of the correlated at least one performance indicator is achieved,
wherein a performance indicator LK 2 reflecting a sufficient buffering capacity of the TP machine is calculated using the following performance parameters:
Pt=time that the packaging machine can be operated from a time the slicing machine stops using buffered portions,
Wt=refill time comprising loading time Lt of the slicing machine plus transport time Tt of a first portion after restarting the slicing machine from the slicing machine to a feeding point of the packaging machine.