DE102018106938B4 - Monitoring system for the production of confectionery by means of an industrial production plant and movable measuring form - Google Patents

Abstract

Monitoring system for the production of confectionery by means of an industrial production plant (14), through which the molds are conveyed and thus reach various processing stations (15, 16, 17, 18, 19) of the production plant (14), the entire conveying route of the production plant (14 ) is divided into defined route units, comprising at least one mold which is provided with at least one sensor (8, 9, 10, 11, 12), an electronics unit (3, 3a, 3b, 3c) and a battery (7), see above that the casting mold forms a measuring mold (1, 26, 27), with measured values being recordable with the sensor of the measuring mold, with the electronic unit (3, 3a, 3b, 3c) having a wireless transmission interface (6) and furthermore a base station (21 , 21a) is provided, so that measured values recorded by the sensor (8, 9, 10, 11, 12) can be transmitted wirelessly to the base station (21, 21a), with a position detection means (4) for detecting the position data of the Me ssform (1, 26, 27) that an allocation means (5) is additionally provided, with which the measured values can be allocated to the position data of that point on the conveyor line at which the measurement form is located at the time of the measurement.

Description

The invention relates to a monitoring system for the production of confectionery by means of an industrial production plant, through which casting molds are conveyed and thus reach various processing stations of the production plant, the entire conveyor section of the production plant being divided into defined section units, comprising at least one casting mold which is equipped with at least one Sensor, an electronics unit and a battery is provided, so that the casting mold forms a movable measuring mold, with measured values being recordable with the sensor of the measuring mold, with the electronics unit having a wireless transmission interface and a base station also being provided, so that recorded by means of the sensor Measured values can be transmitted wirelessly to the base station, a position detection means being provided for detecting the position data of the measurement form, that an allocation means is additionally provided with which the measured values can be allocated nd to the position data of that point on the conveyor line where the movable measuring form is located at the time of the measurement.

The promotion of the casting molds through the production plant is preferably a cyclic promotion. However, designs are also known which continuously convey the casting molds through the production plant, if necessary the processing stations are then adapted and prepared accordingly in order to be able to produce without the casting molds temporarily stopping.

In principle, it is known that confectionery can be poured from liquid, low-viscosity masses. On an industrial scale, this usually takes place on production plants with which, for example, tabular articles such as chocolate or hollow bodies are produced using suitable casting methods and devices. For the production of gummy bears or similar articles from so-called mogul mass, either molding boxes filled with powder are used, into which a hollow negative mold of the shape to be produced is stamped, or so-called powder-free molds are used, which are made of silicone for the purpose of good moldability of the article or made of aluminium, which may have a non-stick coating. Molds made of polycarbonate are convenient and widely used for the production of articles made of chocolate. Such production plants can have a circulating conveyor line, so that the casting molds can circulate in an endless loop. All the necessary processing steps take place during one cycle, including the molding of finished articles and, if necessary, the cleaning of the mold so that it can be used again to form articles. The monitoring system proposed here can be used for all types of confectionery and plant types mentioned.

The casting molds can be transported along the conveyor line through the production plant with electromechanical drive devices, such as chain drives with cams, toothed belt drives or pneumatic feed. They pass through the different processing stations of the production plant, in which individual manufacturing steps are carried out. Processing stations can be provided in which the casting mold is conditioned for certain production steps, for example heated or cooled. For filling with confectionery mass, they are fed to a processing station with a pouring station or an extruder or an inserter for confectionery material. In the case of a hollow body production facility, molds that can be closed and reopened may be required. Typically, a work station is provided for molding the molded article, i.e. the article is released from the mold and can then be passed on to a further manufacturing step or packaging.

In this process, the circulating forms are exposed to various mechanical influences, such as acceleration, shock, vibration, compression and stretching. Likewise, a mold can change its position, for example, get into an inclined position, for example when passing through a processing station, which turns the mold upside down and back. Furthermore, the mold is subjected to various external influences, such as different temperatures, fluctuating humidity and pressure, and air currents, e.g. from fans in a cooling station.

A monitoring system is known from the homepage http://www.agathon-moulds.com/de/logtec-datalogger. It provides a measuring form that includes a mold equipped with sensors for documenting various process variables, such as temperature, humidity, air pressure, acceleration.

The known measuring mold is a casting mold that is equipped with the aforementioned metrological extensions and is therefore also referred to below as a measuring mold. In operation, it can be used exclusively for measuring purposes, or it can also be used for the production of confectionery, because the basis of the measuring mold is a mold with mold cavities, in which the cast confectionery mass can be given shape. It is possible in this way, even such To record process variables that relate to the mold filled with confectionery mass.

The monitoring system should be able to document temperatures such as the chocolate temperature during pouring, the temperature during cooling and the chocolate temperature during demoulding. In addition, parameters such as uneven transport of the measurement form, air pressure during cooling, measurement of a vibration process, stress on the measurement form during demoulding or conditions during the washing of the measurement forms should be documented, whereby a moisture sensor may have to be removed before the washing process.

The various measurable temperatures or measured temperatures can be assigned to the individual processing stations by means of a plausibility check or by extrapolating the position of the mold based on a hypothetical speed of the mold. The chocolate temperature during pouring differs significantly from the chocolate temperature during demolding or from the temperature in the cooling station.

The process variables documented in this way can then be read out with a cable via a USB interface or wirelessly via a Bluetooth interface and can then be evaluated. In this way, they serve to monitor and optimize the industrial production of confectionery and are intended to form a database that is aimed at increasing the efficiency of confectionery production.

The documented data can be read from the known measurement form via the USB interface or the Bluetooth interface. The monitoring system then offers the possibility of viewing the data with the aid of software. The software can be installed on a computer, smartphone or tablet.

The disadvantage of the known monitoring system is the need for a powerful power supply for the USB or Bluetooth interface. Batteries with low storage capacity are impractical because they have to be replaced too often or recharged too frequently in industrial operation. In order to increase the operating time, a larger battery can in principle be used, but this increases the mass of the modified mould. In a production plant for confectionery, a mold is not only moved in translation. Molds sometimes need to be raised and lowered or inverted (turned over), possibly twisted, to form confectionery items. Casting molds are also occasionally shaken, for example to evenly distribute freshly filled confectionery mass or to allow air bubbles to rise and escape by shaking if they are undesirable in the confectionery mass.

If the measuring mold is also to be used to shape the confectionery mass, it must be taken into account that the metrologically modified mold weighs more than a regular mold without modification. The increased weight can be detrimental in certain processing stations of the production line when the measurement form has to be lifted, turned, twisted or jogged. The heavier the modified casting mold, the more unfavorable this is for the relevant processing stations of the production plant.

From the WO 2017/001234 A1 is known a plant for the production of food, in particular a chocolate plant, with at least one treatment station and with at least one industrial robot, which comprises at least one effector with at least one receptacle for at least one product carrier and at least one manipulator for transferring the at least one product carrier, the industrial robot additionally comprises at least one control device and preferably at least one associated processing device, the control device being set or adjustable in such a way that the product carrier can be shaken, turned, rotated, displaced, lifted, preferably at and/or opposite a treatment station and/or between two treatment stations , can be lowered, blown up, sucked off, cleaned, stacked and/or unstacked, knocked out, emptied, filled, temperature controlled and/or, in particular under sensor control, can be moved along a predeterminable path.

the DE 10 2008 053 200 A1 proposes a device for monitoring the storage and transport of goods that change as a result of environmental influences, which has a digital logic with data memory, several sensors for measuring different storage and transport conditions, a transmitting and receiving device for near-field communication with at least one antenna designed as a coil and a downstream switching circuit for sending and receiving and a chargeable energy store and a bistable display, with all the components being arranged on a circuit carrier to form a flat unit and with the digital logic carrying out an evaluation of the condition of the goods as a function of the sensor signals, the result of which can be delivered to the bistable display.

the DE 20 2011 105 052 U1 relates to a container for receiving goods, in particular transport containers for food, with an electronic seal, the electronic seal having: at least one sensor for detecting at least one influencing variable affecting the condition of the transported goods; a transponder for the contactless transmission of data, the transponder being coupled to the at least one sensor, so that the at least one influencing variable detected by the sensor can be called up via the transponder; a display for displaying the at least one influencing variable detected by the sensor, the display changing its appearance at least once depending on the at least one influencing variable.

The invention is based on the object of proposing a monitoring system which at least improves the accuracy of the position detection.

This object is solved by a monitoring system according to claim 1.

It was found that the measured values are more useful for optimizing production and protecting the casting molds, the more precisely it can be determined at which point along the conveyor line a measured value was recorded. Since the new monitoring system has a position detection means and an allocation means, all measured values recorded by the measurement form can be precisely allocated to the corresponding position along the conveyor line where the relevant measured value was recorded. The assignment of measured value and position is significantly improved compared to an indirect determination of the position, which is based on the plausibility of measured values or on the consideration of an assumed system speed or indirect determination based on acceleration data.

In the proposed monitoring system, the electronic unit of the measuring form expediently contains a logic for collecting recorded measured values. In addition, the transmission interface is designed as active data transmission electronics, which is able to wirelessly transmit all measured values in so-called real time.

Many different sensors can be arranged on the measuring form, such as acceleration sensors, including multi-axis designs, gyrometers, magnetic sensors, temperature, humidity and air pressure sensors, as well as sensors that can detect mechanical stress on the measuring form, for example strain gauges (DMS), with which a Deformation of the measurement form can be detected. The sensors are attached individually for each measuring form type. The appropriate location for the attachment of such sensors can be determined, for example, by means of a finite element analysis of the measurement form. The design of the measuring form can also be planned using FEM analysis in order to optimize it for the inclusion of sensors. All sensors are installed according to hygienic aspects. The sensors as well as the electronics unit and battery can be permanently connected to the measuring form, usually on the underside of the measuring form. In the case of a mold made of plastic, components such as sensors, electronic unit, battery, etc. can be cast so that they can only be separated again by destroying the material of the mold. The measuring form can also consist of another material, for example silicone or aluminum. Alternatively, such components can also be detachably connected to the measuring form, preferably covered and secured in such a way that loss during operation is avoided.

An essential aspect of the invention is seen in the provision of the combination of measured value and position data of the measuring form. The position data assigned to a measured value always corresponds to that position (measurement position) at which the relevant measured value was recorded, ie the relevant measurement position along the conveyor line of the production plant. Expediently, unambiguous data sets are formed that contain the position/measured value(s). Different parameters can be recorded simultaneously at a position, so that the data set contains the position and several measured values can be assigned to this position. For example, individual measured values relating to certain parameters can be compared, which were recorded at the same measuring position within the conveyor line after several rotations of the measuring form. The proposed monitoring system increases comparability and improves the database that can be built up with these datasets. Another positive aspect is the almost simultaneous traceability of production, whereby all parameters recorded with the measuring form are immediately visible and can be evaluated.

If the proposed measuring form is in a processing station with which confectionery mass can be filled into a mold, for example a pouring station or an insert for confectionery mass, then this processing station is preferably stopped and the measuring form is not used to produce confectionery items. In principle, it is possible to pour in the confectionery mass because the measuring mold includes a mold whose mold cavities are intact, but used molds have to be checked regularly which, in the case of a measurement form, could affect the sensors and other components. Since washing the measuring form is generally avoided, for reasons of hygiene it is advisable not to fill it with confectionery mass. In certain cases, however, filling with confectionery mass may be necessary, for example when properties of the measuring form are to be measured in the filled state. It should also be borne in mind that the electronics unit, battery and sensors generate heat during operation, which can adversely affect the quality of the confectionery items.

The wireless transmission interface is preferably designed as a radio system that transmits and receives in a frequency band released for industrial purposes (ISM band—Industrial, Scientific and Medical Band). As an example, in Germany the 868 MHz ISM band is an unlicensed ISM band that could be used for the invention.

In other countries, other frequencies may be freely available for this purpose.

The monitoring system is preferably designed to be bidirectional, so that the transmission interface can also be used to transmit data from the base station to the measuring form or to its electronics unit, for example the start and stop of a measurement can be triggered by a signal that is transmitted from the base station to the measuring form or the measuring rate can be set/changed by a signal transmitted to the measuring form.

Additional antennas and/or amplifiers (repeaters) for the radio signal can be used to achieve the radio range required for an industrial production plant.

The measurement rate of the sensors used can range from three readings per second to three readings per hundredth of a second. In this case, a battery can be used which can achieve a service life of approx. 4 years for certain elementary sensors with a measured value per second. For example, a commercial type CR123A battery, which has a charge of approximately 1200 mAh, can be used for the purpose according to the invention. With a reading per hundredth of a second, their lifespan can be around 6 months.

When a critical condition is detected, a fast response time can be achieved, which can be as low as 3 milliseconds. The monitoring system can, for example, carry out a safety shutdown very quickly.

The allocation means is expediently provided within the electronic unit of the measuring form. Alternatively, it can be provided in the base station or arranged within an evaluation unit connected downstream of the base station. It can even be arranged as part of the monitoring system so that it extends into the plant control. It can be arranged in the system control. It then serves as a kind of connection between the system control and the monitoring system according to the invention.

A further development provides that the electronics unit includes an intermediate memory in which measured values and assigned position data can be combined and stored as a common data set.

At least one logical shift register can be provided for detecting the position data of the measurement form, or an RFID data carrier (RFID chip) can be arranged on the measurement form and RFID reading heads can be provided along the conveying path. A position detection using an RFID data carrier on the measuring form requires a transponder, which should be arranged stationary on the transport route. The transmission of position data in this way is very reliable, since RFID chips are robust and not prone to errors. The risk of an incorrect position being determined is very low. In the case of existing production systems that already include RFID chips for other purposes, an existing transponder can also be used to read out RFID chips that are provided for the purpose according to the invention. It is then not necessary to upgrade or convert an existing production system with an RFID chip. This makes retrofitting the monitoring system according to the invention inexpensive. A further advantage is that when determining a position or an intermediate position, the measurement forms can be clearly assigned by the RFID chip together with the stationary transponder.

Another alternative provides a position sensor on the measuring form and a position transmitter outside. Such systems represent a kind of "GPS" in small format, which is not available globally, but limited to smaller distances for industrial sites and halls. Modules that send position data and corresponding position sensors that receive this position data are available. Position data can be recorded in blocks. A block is, for example, a section of a conveyor line. The more transmitters are arranged along the conveyor line, the more precisely a position sensor of the measuring form can determine the correct position coordinates. The advantages of this variant are high reliability and it is a cost-effective alternative.

The simplest solution for recording the position data is a counting device with which the cycle of the system can be counted (system cycle). A cycle refers to the conveying movement with which a casting mold is conveyed out of a processing station and at the same time the next casting mold is conveyed into this processing station, with the casting molds being stopped between the cycles in order to be able to carry out a processing step in the respective processing station . The cycle time of a production plant refers to how many molds per unit of time (e.g. per minute) are processed in the production plant or to the output of the production plant, i.e. how many molds with finished articles the production plant produces per minute. With a counting device for the cycles, it is then always possible to draw conclusions about the current position of each casting mold or measuring mold.

The embodiment with a counting device for the cycles of the system represents the simplest variant for position detection. However, individual processing stations of a production system usually have their own drives and phase shifts can occur between the drives of different processing stations, which affect the transport movement of the casting molds. This can result in deviations between the position determined by counting and the actual position of the measuring form. The counting device counts the system cycles from the time the measuring form is inserted into the production system. In order to assign the exact position, it is necessary to always place the measuring form at a defined position in the confectionery system.

The counting device obtains the system cycle, which is to be counted, from a central drive, which is used as the master axis that generates the cycle. However, this does not take into account phase shifts from other drives of individual processing stations. Therefore, the accuracy of the recorded position of a measurement form is rather rough, certain inaccuracies have to be tolerated with this version. An advantage is that a counting device for the system cycle can be easily retrofitted, so that older production systems can also be retrofitted in this way.

Alternatively, the position data can be recorded using a logical shift register. In addition, the logical shift register can expediently be in the form of a logical presence shift register, with which a presence signal for the presence of the measuring mold in question and/or casting mold in the corresponding line unit can be generated per line unit of the conveying line.

In a production plant for confectionery, a casting mold is usually transported in cycles to individual processing stations, where it is stopped and a processing step is usually carried out before the casting mold is transported further. If the position detection means is in the form of a logical shift register, then the cyclical transport of each casting mold or measuring form is mapped in a logical circuit of the shift register, preferably relating to the entire production plant.

The shift register includes software running on suitable hardware.

In the case of a circulating production plant in which casting molds can cyclically circulate in an endless loop, a shift register with a data ring memory is preferably provided. It depicts the entire circulating conveyor line of the production plant in a virtual ring shape. The virtual number of possible positions in the data ring memory corresponds to the number of positions that exist within the conveying path and can actually be occupied by a casting mold/measuring mold.

Each line unit of a conveyor line of the production plant can be mapped in the shift register with its own dedicated memory area in the register memory. This makes it possible to record the position of a measuring form precisely, even if a conveyor unit has its own transport device and is provided with a separate drive, because any phase shift of the separate drive relative to a central drive is then also recorded in the shift register possible if the central drive is used as the clocking (virtual) master axis.

In principle, the shift register receives a signal from the system control about the system cycle with which the production system transports the casting molds along the conveyor line in cycles. The shift register, which is part of the monitoring system, is expediently arranged as an accessory in the plant control of the production plant. This results in an interface between the system control and the monitoring system according to the invention. In the proposed embodiment, this means that the position detection means, which is designed as a shift register, is combined with the system control. The shift register can be provided in software hen that can be installed on suitable hardware of the system control. Alternatively, suitable hardware can be added that can be connected to the system control via an interface.

In addition, a shift register offers the possibility of storing further data/information/measured values and evaluating them in order to map the condition (status) of the casting and measuring mold. At the same time, the shift register also assumes the function of the assignment means, which brings together the data/information/measured values on the one hand and the associated position data of the measurement form on the other. Thus, in this embodiment, the assignment means, which is part of the monitoring system according to the invention, is also arranged in the system control and intertwined with it.

If the monitoring system is provided with the shift register proposed above, which integrates the position detection means and the assignment means, then this monitoring system can be used to appropriately influence the system control or individual system parts of the production system, for example system parts can be prepared for the arrival of the measurement form.

With this information and by means of a set of rules, it is possible, for example, to draw conclusions about the mechanical condition of the production plant and to assess this, in particular the mechanical condition of the transport device and the aggregates involved in the production plant, always in exactly the right position, at which the measuring form has the appropriate recorded information/measurements. In the event of significant deviations from the set of rules, immediate intervention can be made and the transport device can be readjusted or repaired on this section of the route before damage occurs to the production plant and in particular to the casting molds. For example, it can be used to detect contamination of confectionery items caused by plastic abrasion from measuring forms. Contaminated items can then be discarded. The temperature of the mold can also be recorded and a decision can be made using the set of rules as to whether the temperature is acceptable for the manufacturing process.

In connection with a set of rules, the shift register can act as an "intelligent" shift register, which takes into account comparison parameters/comparison data of the set of rules, for example regarding the position, the temperature, the acceleration, etc. In this way, the shift register not only delivers data/data sets to the evaluation unit, but also provides data/data sets relating to the measurement form, which can be sent to the system control and used there in order to improve production.

Although the measured values relate directly to the measuring form, conclusions can also be drawn about neighboring molds that precede the measuring form or follow it in the transport section, but which do not have their own sensors and are not prepared as a measuring form.

If the measuring form is moved through the production plant in cycles, then the data/data sets are also moved synchronously through the shift register and the transport movement is virtually digitally mapped. With the shift register, the position of the measuring form is always known very precisely. The relevant data/information/measured values are known for each position and are clearly assigned to the corresponding position. In addition, the position and the associated data/information/measured values can be accessed immediately.

The embodiment which has a shift register as allocation means is considered to be a particularly useful and most efficient embodiment of the invention. A position in the shift register always represents a position of the measurement form within the transport route of the production plant. In addition, it is useful that the shift register can be used to measure many different parameters for each position along the transport route or for each position from which measured values are desired can be saved. Measured values can also be recorded repeatedly for each cycle of the measuring form, with either a measured value from the previous cycle being deleted or overwritten, or the earlier measured value being retained and the new measured values added and updated in a row. With such series of measured values, a database can be set up and experience can be gained.

A further benefit is seen in the fact that there is a data link between the base station and the evaluation device for which a wireless second transmission interface is provided. Like the first transmission interface, the second transmission interface is preferably a radio system that transmits and receives in a frequency band (ISM band) released for industrial purposes.

The area of use can be expanded if at least the second transmission interface designed as a radio system is part of a wireless data network which can be coupled to a system controller of the industrial production system. The production plant can include, for example, an Ethernet bus system, for example an industrial bus system, such as the ^ProfiNet® system from Siemens. Then the proposed monitoring system provides a suitable interface to couple the radio system to the bus system of the production facility. In this way, the recorded measured values and associated position data can be transferred to the system control and used there as a signal for adjusting the system control. The data arriving from the base station can be used for comparison with target data that is expected for the corresponding position of the conveyor line. The system control can be used to check whether there is a deviation and whether the deviation complies with defined limits or if it is exceeded, a system command must be generated immediately in order to set a corresponding parameter of the production system differently or, in a critical situation, even stop the production system to force production plant. It is also possible to generate a warning signal to alert operating personnel to certain circumstances that require attention. Certain limits can thus be stored in an electronic set of rules and individual limit values for the respective measured parameters can be specified for all or for certain positions, or for all only for certain distance units along the conveyor route. Suitable countermeasures can be used immediately to react to harmful influences on the casting mold/measuring mold. It is considered a great advantage to be able to counteract a defect in a casting mold or a failure of the casting mold at an early stage. Limit value monitoring can be multi-level, for example a warning as the first level and stricter measures as a further level, etc.

An important aspect of using the measuring form is the regular and/or demand-oriented checking of the system settings. In this way, all external influences on a measuring form can be measured and controlled. In this way, it is possible to indirectly monitor how long a mold or a set of several molds can be subjected to mechanical stress and it can be sorted out in good time before the mold is likely to be destroyed and possible consequential problems, e.g. plastic splinters from a burst mold fall into the poured confectionery product. In particular, mechanical influencing variables such as expansion, compression and impacts, which affect the casting mold and could lead to a defect, can be checked.

The evaluation unit expediently has a computer on which evaluation software for data evaluation can be installed, the evaluation unit also being able to be coupled to the plant control of the production plant via the second transmission interface.

Handling can be improved if the battery of the measurement form is designed as a rechargeable battery, or rechargeable battery, and a charging station is also provided, which provides a defined charging position for the measurement form in order to charge the battery in the charging position.

The monitoring system can be further improved if the charging station can be integrated into a production plant for confectionery. It can act as a kind of loading station for the measuring mold, from which the casting mold modified as a measuring mold can be moved back into the conveyor line of the production plant.

Handling can be simplified if the charging station can transfer energy for charging without contact using a battery prepared for this purpose.

The charging station can be set up in such a way that the measuring form can be removed from the transport route for the duration of charging and placed in a loading position. In the charging position, energy is transferred without contact to the rechargeable battery, for example by means of inductive coupling in a nearby electromagnetic field. For this purpose, a stationary electrical voltage source can be provided, which supplies a transmitting element which is fixedly arranged in the charging station and which in turn is provided with a permanently installed induction coil. The induction coil interacts in a contactless manner with elements that are assigned to the measuring form and are movable with it, namely a receiving element and a coupling coil. When the gauge is in its loading position, the stationary induction coil is close to the gauge. The coupling coil is arranged within the measuring form in such a way that it is also at a short distance from the induction coil. This ensures that a change in the electromagnetic field generated by the induction coil generates a voltage in the coupling coil and a charging current is available for charging the battery.

In order to be able to remove the measuring form from the transport path and move it back into the loading station, support elements are provided parallel to the transport direction, which are arranged on opposite side edges of the measuring form. The two carrying elements are prepared in such a way that they can be moved up and down together and carry the measuring form. In In a starting position, the carrying elements are below the transport level of the casting molds or the measuring mold. When a measurement form has reached the loading station, the support elements are moved upwards and the measurement form is lifted out of the transport path until it has reached its loading position. It can remain as required for a full or partial charge and then be lowered back to the transport level.

The effectiveness of the contactless energy transfer can be improved if the positioning of the coupling coil is optimized relative to the induction coil. The above suggestion includes bringing that side of the measuring form on which the coupling coil is arranged as close as possible to the induction coil. In addition, other measures are useful to avoid a lateral offset and/or a vertical offset of the coupling coil relative to the induction coil. For this purpose, the measuring form can be provided with holding magnets, preferably on the side of the coupling coil, which interact with correspondingly positioned magnetization points within the charging station. In this way, an optimal position between the induction coil and the coupling coil can be ensured.

As part of the monitoring system, a measuring mold is proposed with a mold on which at least one sensor is arranged, as well as with an electronics unit and a battery and with a wireless transmission interface for bridging a data link to a base station, the mold (measuring mold), or the electronics unit has a position detection means for detecting the position data of the measuring mold, with which position data can be detected while the mold is being moved along the conveying path of a production plant for confectionery.

Suitable countermeasures can be used immediately to react to harmful influences on the casting mold/measuring mold. It is considered a great advantage to be able to counteract a defect in a casting mold/measuring mold or a failure of the casting mold/measuring mold at an early stage.

A sensor for detecting the contraction of the chocolate mass (contraction sensor) is considered to be a helpful sensor for the measuring mold, in particular if this is provided for the production of chocolate articles. Unlike other confectionery masses, chocolate has the property of changing its crystallization structure during solidification in such a way that a detectable contraction takes place.

A combination of ultrasonic transmitter and ultrasonic receiver is proposed as an example of a suitable contraction sensor, which couples structure-borne noise with ultrasonic frequency into the material of the casting mold, which forms the basis of the measuring mold. The structure-borne noise continues into the chocolate body, is reflected and recorded by the ultrasonic receiver. The onset of contraction of the chocolate mass changes the coupling of the chocolate to the mould. It is becoming increasingly difficult to couple structure-borne noise into the chocolate the further it detaches from the mould. In this way, the degree of solidification of the confectionery mass can be detected directly. The optimum point in time for shaping the confectionery item can thus be determined with sufficient accuracy. In the case of a chocolate confectionery item, the molding is appropriate at a time when the contraction of the chocolate has at least begun. Before that, the chocolate still sticks to the mold, so that a mold can fail. This would disrupt the production process and result in rejects.

The energy efficiency of the production plant can be improved with a sensor for detecting a contraction of the chocolate. In particular, the cooling of the molds can be optimized in such a way that the chocolate items are sufficiently contracted or conditioned in good time when they reach the shaping station so that they can be shaped reliably. For this purpose, for example, the temperature of the cooling station can be influenced or the throughput speed of the casting mold through the cooling station or other suitable parameters that can cause a contraction in time for the shaping station. Without knowing when the chocolate contracts, more cooling is used than is necessary to ensure that the chocolate solidifies reliably. This means that more energy is used than actually required. The proposed contraction sensor reliably solves this problem.

• 1a Eine Gießform eines Überwachungssystems, welche als Messform mit Messeinrichtungen ausgestaltet ist,
• 1b die Unterseite der Messform gemäß 1a,
• 2 ein erstes Ausführungsbeispiel eines Überwachungssystems, schematisch dargestellt anhand eines Ausschnitts einer Produktionsanlage für Süßwaren,
• 3 eine Visualisierung der Messung eines an der Messform vorgesehenen Sensors zur Schwingungsmessung,
• 4 eine Visualisierung von Auswertungsbeispielen der Schwingungsmessung gemäß 3,
• 5 ein zweites Ausführungsbeispiel eines Überwachungssystems,
• 6 ein drittes Ausführungsbeispiel eines Überwachungssystems,
• 7 ein viertes Ausführungsbeispiel eines Überwachungssystems,
• 8 ein fünftes Ausführungsbeispiel eines Überwachungssystems
• 9 eine ausschnittsweise Darstellung einer Ladestation für eine wiederaufladbare Batterie der Messform.

The invention is described below with reference to several figures, which show:

• 1a A mold of a monitoring system, which is designed as a measuring mold with measuring devices,
• 1b the bottom of the measurement form 1a ,
• 2 a first embodiment of a monitoring system, shown schematically using a section of a production plant for confectionery,
• 3 a visualization of the measurement of a sensor provided on the measuring form for vibration measurement,
• 4 a visualization of evaluation examples of the vibration measurement according to 3 ,
• 5 a second embodiment of a monitoring system,
• 6 a third embodiment of a monitoring system,
• 7 a fourth exemplary embodiment of a monitoring system,
• 8th a fifth embodiment of a surveillance system
• 9 a sectional representation of a charging station for a rechargeable battery of the measurement form.

In the 1a and 1b a casting mold is shown that has been expanded to form a measuring mold 1, or forms the basis for it. Measurement form 1 is an important part of the proposed monitoring system.

Measuring form 1 is a casting mold equipped with sensors and electronics. It has the usual mold depressions 2 on its upper side 1a, as in 1a to recognize. The mold depressions 2 are basically available for filling with confectionery mass and for shaping confectionery items.

In 1b a perspective of the underside 1b of the measurement form 1 can be seen. An electronic unit 3 is arranged on the underside 1b and, as a component of the electronic unit 3, a position detection means 4 for the position data of the measuring form 1 and, in addition, an allocation means 5 and a transmission interface 6. A battery 7 is provided for the energy supply of the electronic unit and its components.

Connected to the electronics unit 3 are several components, for example sensors such as a temperature sensor 8, a humidity sensor 9, an air pressure sensor 10, an acceleration sensor 11 and a contraction sensor 12. All sensors that require electrical energy are supplied with energy via the battery 7. In addition, strain sensors, pressure sensors, ultrasonic sensors, etc. of measurement form 1 can also be applied (not shown).

The position of the measuring form 1 along a conveyor section of a production plant can be detected with the position detection means 4, so that at the time of each measurement data relating to the position of the measuring form 1 at the respective measurement time are available. The matching position data can then be assigned to each measured value with the aid of the assignment means 5 .

In the present exemplary embodiment, the allocation means 5 is provided on the measurement form 1 and in this example forms part of the electronics unit 3. Alternatively, the allocation means can also be provided outside of the measurement form 1 at another point within the proposed monitoring system.

The electronics unit 3 expediently contains logic for collecting measured values and possibly also for collecting recorded position data. The assignment means 5 is integrated in the logic of the electronic unit 3 in this example. With the transmission interface 6 mentioned, data, measured values and position data are transmitted to a base station 21, which is also part of the monitoring system. In this way, all the data that occurs can be transmitted to the base station 21, i.e. measured values of measurement form 1 as well as position data, provided the position data are generated in the electronic unit 3.

Since the measuring form 1 is provided with an electronic unit 3, there may be reasons not to fill the measuring form 1 with confectionery mass. A mold that is filled with confectionery mess must be cleaned after the finished confectionery items have been formed. There is a washing station for this, in which water and, under certain circumstances, cleaning agents are used. Such a cleaning treatment could under certain circumstances impair the measuring form 1, even if the components of its electronic unit 3 are designed to be water-proof or watertight, this should be carried out cautiously if not avoided.

With the proposed monitoring system, each measured value can now be assigned to the appropriate position immediately after the measurement, at which the measurement form 1 was located at the time of the measurement.

The transmission interface 6 is preferably designed as active data transmission electronics that are able to wirelessly transmit all measured values that occur in real time. This enables rapid evaluation and allows the results to be made available immediately for a system control of the production system.

In 2 a production plant 14 for confectionery is shown schematically and in part. Also, the essential components of the proposed surveillance system shown. The section shows an example of five processing stations of the production plant, namely a casting station 15 as the first processing station, then a shaking station 16, a cooling station 17, a twisting station 18, with which an individual mold can be twisted in order to release finished confectionery items, and a shaping station 19. Furthermore, a plant control 20 is shown, which is part of the production plant. The monitoring system, on the other hand, includes a measurement form 1, which is 1a /1b corresponds to measurement form 1 shown. In the example of 2 this measuring form 1 is currently in the casting station 15. A base station 21 is also shown, which is part of the proposed monitoring system. An evaluation unit 22 in the form of an evaluation computer is provided on the base station 21 . This can be implemented as a PC, for example. A screen 23, which also belongs to the monitoring system, is connected to the evaluation unit 22. The measurement form 1 includes the position detection means 4 for the position data of the measurement form 1 and in particular the assignment means 5, with which the respective position of the measurement form 1 at the time of measurement can always be assigned to the corresponding measured value. The combined data - measured value and position - can then be transmitted to the base station 21. The evaluation can also take place in the logic of the electronics unit 3 and be transmitted to the base station 21 . With the base station 21, the data—measured value and position—as well as the evaluation of this data can be visualized and/or transmitted to the system controller 20 of the production system 14.

A preferably wireless data transmission is provided between the transmission interface 6 of the measurement form 1 and the base station 21 . Likewise, the system controller 20 is preferably wirelessly connected to the base station 21 . Data can be transmitted in both directions (bidirectionally) between the base station 21 and the transmission interface of measurement form 1. In this way, e.g. the sampling rate of a sensor can be changed. Information such as sampling rates can be stored in the electronics unit 3 or in the sensor itself. Because of the bidirectional transferability of data, they can easily be changed, specifically from the base station 21 . A sensor can also be activated or deactivated in this way. For example, a sensor can be deactivated if no measurement is necessary, for example if measurement form 1 is currently passing through a processing station of production plant 14 that does not require monitoring/measurement. Temporarily deactivating sensors can save energy.

A visualization of a measurement is shown in an example in 3 shown. This is what an oscillation behavior f recorded using measurement form 1 looks like, shown graphically as an oscillation curve 24 over time t. It has been detected with an acceleration sensor 11 provided on the measuring form 1 . In the visualization, an upper limit 25a and a lower limit 25b for the vibration are shown as an example, which are stored as a set of rules in the monitoring system. The set of rules can be stored, for example, in the electronic unit 3 of the measurement form 1, in the base station 21 or in the evaluation unit 22. Exceeding the defined limits can, for example, be used to trigger a warning or interference signal. Alternatively, exceeding the limits can trigger a signal that is transmitted directly to the system controller 20 of the production system 14 in order to trigger a reaction there, for example changing a parameter, generating a maintenance request, stopping the system, etc.

An example of a practical application of vibration measurement using an acceleration sensor 11 is shown in FIG 4 explained. There, a vibration behavior f is reproduced over the conveying sections of measurement form 1. Individual sections of the conveyor line are denoted by numbers. Numeral 7 designates a station as a form transition in which an increased vibration behavior occurs. A change in transport is referred to as a form transition. A transport device can sometimes extend through several processing stations, but sometimes a transport device ends and a new transport device begins in a subsequent processing station, so that a transition must take place so that casting molds or a measuring mold can be transported further. The transport devices can be of the same type, for example chain transport, toothed belt transport or others. In addition, the shape transition can also take place between different types of transport devices. Each transition represents a mechanical interface where gaps, edges, etc. can mean a certain disruption in the transport of the moulds. These transitions are potential danger points for the mold. Misadjustments can result in excessive jarring than necessary, which can negatively affect the quality of the confectionery items and even cause damage to the molds. According to the invention, a vibration behavior f is to be considered increased if the values shown in diagram ( 4 ) entered limits are exceeded. In 4 For example, an upper limit 25c is provided at the shape transition. Numeral 8 designates the shaping station 19 of the production plant 14, in which the molds are turned and vibrated to produce finished sweets items can detach and fall onto a conveyor belt. 4 shows a deflection of the oscillation curve in the area of the shaping station 19, this deflection exceeding an upper limit 25d and falling below a lower limit 25e, which are defined in the set of rules. This indicates wear or advanced damage to the mold and allows conclusions to be drawn about the condition of the other molds, for example because their service life is known, but allows conclusions to be drawn about the condition of the production plant. If this limit is exceeded, the set of rules can issue an indication that a processing station needs to be checked or serviced or adjusted, or it can transmit a signal to the system controller 20 in order to initiate a corresponding reaction.

A second exemplary embodiment of a monitoring system is 5 shown. It corresponds to the embodiment of 2 except for one detail, namely the changed arrangement of the allocation means 5. An electronic unit 3a without allocation means 5 is provided. The assignment means 5 is instead arranged in a base station 21a. This alternative simplifies the construction of the measuring form 26 because it can be designed without any assignment means. This alternative can be used, for example, when the position of the measuring form 26 is determined using a simple counting device. A clock signal usually comes from the system controller 20. This information - the clock signal - is passed from the system controller 20 to the base station 21a. The clock signal can thus be converted in the base station 21a into position information and it can then be combined in the assignment means 5 with the measured values which have been transmitted from the measuring form 26 to the base station 21a.

It can be useful to arrange the assignment means 5 outside the measurement form 26 in order to technically simplify the measurement form, for example to arrange fewer electronic components on the measurement form 26 .

A measurement form 26 is therefore provided without allocation means, but which otherwise corresponds to measurement form 1 according to FIG 1a /1b corresponds. The measuring form 26 records the position data and also the measured values by means of the existing sensors (8, 9, 10, 11 and 12). The measured values and position data are then transmitted in parallel to the base station 21a and a common data record is formed from the measured value and associated position data using the allocation means 5 provided there. Again, the base station 21a preferably communicates wirelessly with a plant control 20 of the production plant 14. The evaluation of the measured values, position data and the data sets with the measured values and position data assigned to one another also takes place in the base station 21a.

In a third embodiment of the monitoring system, such as 6 illustrated, the assignment means 5 is assigned to the evaluation unit 22 , which receives the data or data sets—measured value and position—from the base station 21 and can visualize this and the evaluation of the data by means of a screen 23 . Again, a measuring form 26 without assignment means 5 is provided, as in 5 and an electronics unit 3a. Otherwise, the monitoring system corresponds to that of the first exemplary embodiment. This exemplary embodiment represents a simple solution that only requires a sufficiently powerful evaluation unit in order to implement assignment means 5 .

In 7 a fourth exemplary embodiment of the monitoring system is shown, in which a measuring form 27 comprises an electronics unit 3b and sensors, namely temperature sensor 8, humidity sensor 9, air pressure sensor 10, acceleration sensor 11 and a contraction sensor 12. A transmission interface 6 is also provided, which connects the electronics unit 3b wirelessly to the measurement form 27 connects a base station 21b. In contrast, the position detection means 4 for detecting the position data of the measuring form 27 is arranged in a system controller 20a of the production system 14 . In other words, in this exemplary embodiment, a part of the monitoring system according to the invention extends into the system control 20a. The base station 21b is provided with a second transmission interface 6a, which connects it wirelessly to the evaluation unit 22 and also to the system controller 20a. The second transmission interface 6a can of course be provided as an alternative data connection in all exemplary embodiments. In this example, the assignment means 5 for combining the measured values and the position data into a common dataset is also provided in the system controller 20a and is integrated with the position detection means 4, specifically in the form of a shift register SR that includes a register memory. The shift register SR can both record the position of the measurement form 27 and store data/information/measured values matching this position in its register memory as data sets. The base station 21b receives data from two directions. On the one hand, the measured values arrive from the transmission interface 6 of the measurement form 27 to the base station 21b and are forwarded to the shift register SR. If the shift register SR has formed the data sets mentioned, these are also on the base station 21b and can be sent from there to an evaluation unit 22 where they can be displayed and analyzed.

A fifth exemplary embodiment of the monitoring system according to FIG 8th provides a measuring form 28 with an electronic unit 3c provided with a position detecting means having a position sensor 29. The position sensor 29 receives position signals which are emitted by a position transmitter 30 of the monitoring system which is arranged stationary for this purpose. The position transmitter 30 works in the manner of a GPS transmitter, but with a shorter range, which is sufficient for the dimensions of an industrial site or industrial hall(s). A base station 21a in turn includes an allocation means 5. A charging station 31 for the battery 7 of the measuring form 28 is also provided, with which the measuring form 28 can be removed from the transport device or from the conveyor section, charged and returned to the conveyor section. Details of the charging station 31 in the sectional view of 9 shown.

9 FIG. 12 shows schematically a charging station 31 adapted to charge a rechargeable battery 7 arranged on the measuring form 1. FIG. For the duration of the charging, the measuring form 1, which is shown with a dashed line at the level of the transport section, is removed from there, in the present example it is lifted out. This is done with a lifting device 32 which removes the measurement form 1 from the transport section and brings it into a loading position 33 . In the charging position 33, a contactless transfer of energy takes place, in the present exemplary embodiment by means of inductive coupling in a nearby electromagnetic field. For this purpose, a stationary electrical voltage source is provided, which supplies a transmitting element 34 which is fixedly arranged in the charging station and which in turn is provided with a permanently installed induction coil 34a. The induction coil 34a interacts without contact with elements which are assigned to the measuring form 1 and are movable with it, namely a receiving element 35 and a coupling coil 35a connected to it. When the measurement form 1 has been moved into the loading station 31 and has assumed its loading position 33, the stationary induction coil 34a is close to the measurement form 1 but without contact. Within the measurement form 1, the coupling coil 35a is arranged so that it is also close to the induction coil 34a. This ensures that a change in the electromagnetic field generated by the induction coil 34a reaches the coupling coil 35a, so that a voltage can be generated in the coupling coil 35a and a charging current for charging the battery 7 is available.

The mentioned lifting device 32 is used to remove the measuring form 1 from the transport section and bring it into the loading position 33. This is provided with carrying elements 36 and 37, which are arranged parallel to the transport direction on both side edges of the measuring form 1. The support members 36 and 37 can be moved up and down to raise and lower the measurement form 1. In a starting position, the carrying elements are located below a transport level of the casting molds or the measuring mold 1. If a measuring mold 1 has been transported along the conveyor line to the loading station 31, it can then be moved upwards by means of the carrying elements 36 and 37 and brought into their loading position 33 . There it can be fully or partially loaded as required and then lowered into a suitable gap between other molds on the transport level for further use.

Reference List

1

measurement form

1a

top

1b

bottom

2

shape deepening

3

electronics unit

3a

electronics unit

3b

electronics unit

3c

electronics unit

4

position detection means

5

allocation means

6

transmission interface

6a

second transmission interface

7

battery

8th

temperature sensor

9

humidity sensor

10

air pressure sensors

11

accelerometer

12

contraction sensor

14

production plant

15

casting station

16

shaking station

17

cooling station

18

twist station

19

molding station

20

plant control

20a

plant control

21

base station

21a

base station

21b

base station

22

evaluation unit

23

Screen

24

oscillation curve

25a

upper limit

25b

lower limit

25c

upper limit

25d

upper limit

25e

lower limit

26

measurement form

27

measurement form

28

measurement form

29

position sensor

30

position transmitter

31

charging station

32

lifting device

33

loading position

34

transmission element

34a

induction coil

35

receiving element

35a

coupling coil

36

supporting element

37

supporting element

SR

shift register

Claims (12)

Monitoring system for the production of confectionery by means of an industrial production plant (14), through which the molds are conveyed and thus reach various processing stations (15, 16, 17, 18, 19) of the production plant (14), the entire conveying route of the production plant (14 ) is divided into defined route units, comprising at least one mold which is provided with at least one sensor (8, 9, 10, 11, 12), an electronics unit (3, 3a, 3b, 3c) and a battery (7), see above that the casting mold forms a measuring mold (1, 26, 27), with measured values being recordable with the sensor of the measuring mold, with the electronic unit (3, 3a, 3b, 3c) having a wireless transmission interface (6) and furthermore a base station (21 , 21a) is provided, so that measured values recorded by the sensor (8, 9, 10, 11, 12) can be transmitted wirelessly to the base station (21, 21a), with a position detection means (4) for detecting the position data of the Me ssform (1, 26, 27) that an allocation means (5) is additionally provided, with which the measured values can be allocated to the position data of that point on the conveyor line at which the measurement form is located at the time of the measurement. surveillance system claim 1 , characterized in that the wireless transmission interface (6) is designed as a radio system that transmits and receives in a frequency band released for industrial purposes, ISM band (Industrial, Scientific and Medical Band). surveillance system claim 1 or 2 , characterized in that the measuring rate of the sensors used (8, 9, 10, 11, 12) ranges from three measured values per second to three measured values per hundredth of a second. Monitoring system according to one of the Claims 1 until 3 , characterized in that the allocation means (5) is provided within the electronic unit (3, 3a, 3b, 3c) of the measuring form or in the base station (21, 21a) or within an evaluation unit (22) connected downstream of the base station (21, 21a). is arranged. surveillance system claim 4 , characterized in that the electronics unit (3, 3a, 3b, 3c) comprises a logic circuit in which measured values and assigned position data can be stored. Monitoring system according to one of the Claims 1 until 5 , characterized in that at least one logical shift register (SR) is provided for the detection of the position data of the measuring form or an RFID data carrier is arranged on the measuring form (1) and RFID reading heads are provided along the conveying path, or a position sensor (29) on the measuring form (1) and a position transmitter (30) is provided outside, or a counting device with which the system cycle can be counted. surveillance system claim 6 , characterized in that the position data can be determined by means of a logical presence shift register provided for this purpose, in that a presence signal for the presence of the measuring mold in question (1, 26, 27, 28) and/or casting mold in the corresponding line unit can be generated per line unit of the conveyor line . Monitoring system according to one of the Claims 4 until 7 , characterized in that between the base station (21, 21a) and evaluation unit (22) is a data link for a wireless second transmission interface is provided. surveillance system claim 8 , characterized in that the second transmission interface is part of a wireless data network which can be coupled to a plant controller (20, 20a) of the industrial production plant (14). surveillance system claim 8 or 9 , characterized in that the evaluation unit (22) has a computer on which evaluation software for data evaluation can be installed, and in that the evaluation unit (22) is connected to the system controller (20, 20a) of the production system (14) via the second transmission interface (6a). can be coupled. Monitoring system according to one of the Claims 1 until 9 , characterized in that the battery (7) of the measuring form (1, 26, 27, 28) is designed as a rechargeable battery, or rechargeable battery, and a charging station is also provided which provides a defined charging position for the measuring form in order to be in the charging position charge the battery. Measuring mold with a casting mold on which at least one sensor (8, 9, 10, 11, 12) is arranged, and with an electronics unit (3, 3a, 3b, 3c) and a battery (7), and with a wireless transmission interface (6 ) for bridging a data link to a base station (21, 21a), characterized in that the casting mold or the electronics unit (3, 3a, 3b, 3c) has a position detection means (4) for detecting the position data of the measuring mold, with which position data can be detected are while the mold is moved along the conveyor line of a production plant (14) for confectionery.

Images