EP3578251B1 - Digitally crosslinked mixing and/or homogenisation system - Google Patents
Digitally crosslinked mixing and/or homogenisation system Download PDFInfo
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- EP3578251B1 EP3578251B1 EP19179094.8A EP19179094A EP3578251B1 EP 3578251 B1 EP3578251 B1 EP 3578251B1 EP 19179094 A EP19179094 A EP 19179094A EP 3578251 B1 EP3578251 B1 EP 3578251B1
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- 238000002156 mixing Methods 0.000 title claims description 83
- 238000000265 homogenisation Methods 0.000 title claims 7
- 238000012544 monitoring process Methods 0.000 claims description 34
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- 238000012423 maintenance Methods 0.000 claims description 13
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- 238000000034 method Methods 0.000 claims description 12
- 238000011010 flushing procedure Methods 0.000 claims description 9
- 239000002360 explosive Substances 0.000 claims description 8
- 239000006260 foam Substances 0.000 claims description 8
- 238000012546 transfer Methods 0.000 claims description 8
- 238000004140 cleaning Methods 0.000 claims description 6
- 238000007789 sealing Methods 0.000 claims description 4
- 239000002537 cosmetic Substances 0.000 claims description 3
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 3
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- 101100390736 Danio rerio fign gene Proteins 0.000 description 1
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Images
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01F—MIXING, e.g. DISSOLVING, EMULSIFYING OR DISPERSING
- B01F27/00—Mixers with rotary stirring devices in fixed receptacles; Kneaders
- B01F27/80—Mixers with rotary stirring devices in fixed receptacles; Kneaders with stirrers rotating about a substantially vertical axis
- B01F27/90—Mixers with rotary stirring devices in fixed receptacles; Kneaders with stirrers rotating about a substantially vertical axis with paddles or arms
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01F—MIXING, e.g. DISSOLVING, EMULSIFYING OR DISPERSING
- B01F35/00—Accessories for mixers; Auxiliary operations or auxiliary devices; Parts or details of general application
- B01F35/20—Measuring; Control or regulation
- B01F35/21—Measuring
- B01F35/211—Measuring of the operational parameters
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01F—MIXING, e.g. DISSOLVING, EMULSIFYING OR DISPERSING
- B01F35/00—Accessories for mixers; Auxiliary operations or auxiliary devices; Parts or details of general application
- B01F35/20—Measuring; Control or regulation
- B01F35/21—Measuring
- B01F35/212—Measuring of the driving system data, e.g. torque, speed or power data
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01F—MIXING, e.g. DISSOLVING, EMULSIFYING OR DISPERSING
- B01F35/00—Accessories for mixers; Auxiliary operations or auxiliary devices; Parts or details of general application
- B01F35/20—Measuring; Control or regulation
- B01F35/22—Control or regulation
- B01F35/2201—Control or regulation characterised by the type of control technique used
- B01F35/2205—Controlling the mixing process from a remote server, e.g. by sending commands using radio, telephone, internet, local network, GPS or other means
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01F—MIXING, e.g. DISSOLVING, EMULSIFYING OR DISPERSING
- B01F35/00—Accessories for mixers; Auxiliary operations or auxiliary devices; Parts or details of general application
- B01F35/20—Measuring; Control or regulation
- B01F35/22—Control or regulation
- B01F35/2201—Control or regulation characterised by the type of control technique used
- B01F35/2209—Controlling the mixing process as a whole, i.e. involving a complete monitoring and controlling of the mixing process during the whole mixing cycle
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01F—MIXING, e.g. DISSOLVING, EMULSIFYING OR DISPERSING
- B01F35/00—Accessories for mixers; Auxiliary operations or auxiliary devices; Parts or details of general application
- B01F35/20—Measuring; Control or regulation
- B01F35/22—Control or regulation
- B01F35/221—Control or regulation of operational parameters, e.g. level of material in the mixer, temperature or pressure
- B01F35/2214—Speed during the operation
- B01F35/22142—Speed of the mixing device during the operation
Definitions
- the invention relates to a digitally networked mixing and/or homogenizing system, in particular for cosmetic products, with a mixing and/or homogenizing device for mixing and homogenizing fluid, the mixing and/or homogenizing device having at least: a container for receiving fluid, an agitator, with a mixing element arranged at least in sections in the container, as well as a drive device connected to the mixing element for driving the mixing element, a homogenizer connected to the container in a fluid-conducting manner with at least one homogenizer mixing element and a homogenizer operatively connected to the at least one homogenizer mixing element Drive unit, a pipeline system connected to the homogenizer, a remotely operable valve arranged in the pipeline system to conduct fluid, a control device for controlling the drive device and/or the valve, with a processor and a spoke r, a sensor device connected in a data-conducting manner to the control device for determining a measured variable and converting the measured variable into a signal.
- Such mixing and/or homogenizing systems are used, for example, in the cosmetic, pharmaceutical or chemical industry in the production of creams, ointments, pastes or the like.
- the plant systems regularly have at least one container in which the fluid to be mixed and processed is accommodated.
- a stirrer is typically introduced into such a container, which allows mixing of the fluid.
- a homogenizer for homogenizing the fluid is typically connected to the container in a fluid-conducting manner.
- mixing and/or homogenizing devices known from the prior art typically have a large number of lines and valves for fluid transport and for controlling fluid flows.
- a relevant mixing and/or homogenizing system is off, for example DE 20 2014 003774 U1 is known, wherein a mixing and/or homogenizing plant system according to the preamble of claim 1 is disclosed.
- U.S. 2015/238914 A1 also relates to a mixing unit having a frame, a rheology control section and a high volume solids mixing section.
- Plant systems previously known from the prior art typically have sensors for this purpose, which are connected to a control device in a data-conducting manner.
- the control device controls a large number of actuators, for example relating to the drive of a mixing element, valve positions, and the like.
- a disadvantage of the described prior art is that the control device and the measured variables determined by the sensor device can only be accessed to a very limited extent and only by an operator who is in the immediate vicinity of the mixing and/or homogenizing system. It is therefore not possible to monitor operating data or to adjust operating data without direct contact with the system.
- Another disadvantage is that only a very limited number of measured variables are recorded and life cycle information and failure probabilities of individual components cannot be determined or can only be determined with great difficulty.
- the invention was based on the object of further developing a mixing and/or homogenizing plant system in such a way that the disadvantages found in the prior art are eliminated as far as possible.
- a mixing and/or homogenizing plant system was to be specified which allows improved status monitoring of essential operating components and at the same time enables largely location-independent access to the components of such a plant.
- the object is achieved in a mixing and/or homogenizing system of the type mentioned at the outset by a data transmission device connected to the control device in a data-conducting manner, a data network that can be connected to the data transmission device in a data-conducting manner, and a remote control device that can be connected to the data network in a data-conducting manner and is set up to transmit data using the To send data network to the data transmission device and / or to receive it, the remote control device being set up to perform the following: evaluation of sensor data and / or process information for predictive maintenance of a wear component of the mixing and homogenizing system.
- Such a proposed digitally networked mixing and/or homogenizing plant system makes it possible in a simple manner to transfer data, in particular operating data and the like, from a mixing and/or receiving, evaluating and monitoring the homogenizing device.
- an authorized user can access the control device of such a mixing and/or homogenizing device almost independently of location in order to influence and optimize the mixing and/or homogenizing process.
- An operator or maintenance technician no longer has to personally go into the vicinity of a plant and gain on-site access to the control device for the purpose of operational data monitoring and control adjustment.
- Overall not only can operating and maintenance costs be saved, but the operation of such a mixing and/or homogenizing system can also be influenced more quickly and cost-effectively.
- the invention is further developed in that the mixing and/or homogenizing device has one, several, or all of the following components: stationary cleaning device, transfer system, sealing liquid system, temperature control system, vacuum system, lid lift.
- the components or assemblies described have proven to be particularly advantageous for carrying out industrial mixing and/or homogenizing applications in which large quantities of fluid are to be processed with high processing quality.
- the data-carrying connection between the sensor device and the control device is designed as at least one of the following: Profibus, Ethernet, direct connection. All three types of data connection have proven to be reliable, fast data-carrying connections and have a sufficient data throughput, in particular for the transmission of the multiple sensor data from the sensor device to the control device. The sensor data can thus be transmitted to the control device essentially in real time.
- the data transmission device preferably has a switch.
- the data network is designed as one of the following: Ethernet, wireless local area network, virtual private communication network.
- Ethernet Ethernet
- wireless local area network virtual private communication network
- virtual private communication network an Ethernet connection with a high data throughput can be advantageous.
- the data network can also be designed as a wireless local area network for particularly flexible access.
- a high one Security-compliant connection from remote locations can be established in essentially real-time via a Virtual Private Communications Network (VPN).
- VPN Virtual Private Communications Network
- the remote control device has at least one of the following user levels: internal user level, external user level, internal IT level.
- the scope of the access authorization can be adjusted, i.e. whether a specific user is only allowed to view a selection of operating parameters, such as sensor data, and whether another user is also allowed to influence the Control of the mixing and/or homogenizing plant system. It can also be differentiated according to where the user is located, i.e. whether he is in close proximity to the mixing and/or homogenizing device, in the same manufacturing environment (factory), in the plant manufacturing company, or at any one of these distant place.
- the invention is further developed in that the internal user level and/or the external user level have a PC client and/or a mobile client. It is thus possible both within the internal user level and within the external user level to set up a data connection both using a personal computer and a client running on it, and using a mobile terminal device which also runs a relevant client.
- Another alternative preferred embodiment is characterized in that the internal user level is connected to the data transmission device via a local network, in particular Ethernet or a wireless local network, and/or the external user level is connected to the data transmission device via a virtual private communication network.
- the connection of a stationary or semi-stationary personal computer is possible by means of an Ethernet connection, which enables a secure and broadband connection.
- the mobile client is preferably connected via a wireless local area network (WLAN), with high data rates and high network security being able to be achieved here as well.
- WLAN wireless local area network
- the external user level is preferably connected via a virtual private Communications network, which ensures secure data transmission with the data transmission device, virtually independent of location.
- the invention is further developed in that the internal IT level has at least one server, which in particular has an interface server, in particular an Open Platform Communications (OPC) server, and/or an application server.
- OPC Open Platform Communications
- the application server essentially serves as a server for the PC clients and the mobile clients of the internal and external user level.
- the operating data, such as in particular the sensor data, of a mixing and/or homogenizing device can be recorded, processed and evaluated by means of the OPC server, and at the same time the control device can be influenced as required.
- the internal IT level is preferably connected to the data transmission device via a local network, in particular Ethernet.
- the Ethernet connection represents a broadband and secure connection type.
- the sensor device has at least one of the following sensors: temperature sensor, pressure sensor, flow sensor/flow sensor, end position sensor, conductivity sensor, turbidity sensor/float sensor, viscosity sensor, pH value sensor, foam sensor, filling level sensor, empty notification sensor, image sensor, in particular video camera, storage monitoring sensor , wear sensor, UV light sensor, flushing device monitoring sensor for detecting a non-explosive atmosphere, water sensor, torque sensor, weight sensor, speed sensor.
- the sensors and sensor types mentioned have proven to be particularly suitable and advantageous for use in a mixing and/or homogenizing device for monitoring a wide variety of operating states and component positions as well as the fluid states.
- the end position sensor preferably senses the end position of at least one of the following: valve position, manhole position, cover position, coupling floor installation. The correct positioning or a correct closure of operating and maintenance openings of the mixing and/or homogenizing device can thus be ensured.
- the bearing monitoring sensor is preferably designed as a vibration sensor.
- a detection of vibrations occurring in a bearing has proven to be particularly suitable for monitoring a bearing condition.
- An increase in vibrations or oscillations in a bearing allows conclusions to be drawn about bearing wear and also enables preventive maintenance events to be carried out if, for example, the vibrations determined indicate that a bearing will fail in the near future and needs to be replaced.
- the container has one, several or all of the following sensors: temperature sensor, pressure sensor, end position sensor, foam sensor, filling level sensor, empty notification sensor, image sensor, weight sensor.
- sensors have proven to be preferable to ensure comprehensive and accurate monitoring of the processes starting in the container and in the immediate vicinity of the container.
- the agitator also preferably has one, several or all of the following sensors: bearing monitoring sensor, wear sensor, flushing device monitoring sensor for detecting a non-explosive atmosphere, speed sensor, torque sensor.
- the homogenizer preferably has one, several or all of the following sensors: pressure sensor, bearing monitoring sensor, wear sensor, drive monitoring sensor of a flushing device, speed sensor, torque sensor.
- sensors described here also enable extensive condition monitoring and early detection of possible failure events to reduce downtimes.
- the sensor device has at least one analog/digital converter for converting an analog sensor signal into a digital sensor signal.
- the invention is further developed in that the remote control device is set up to carry out at least one of the following: evaluation of sensor data and determination of process information, in particular in real time, Archiving of sensor data and/or process information.
- the operator is preferably shown a large number of sensor data and process information. He can then obtain a comprehensive overall picture and also detailed information about individual plant areas and process steps. Furthermore, it is preferred that the evaluation of sensor data takes place using statistical methods and that historical data is compared and correlated with the sensor data determined in real time, in particular for the early detection of undesirable developments and maintenance events.
- sensor data and/or process information is also used for predictive maintenance of wearing components. Based on statistical evaluations, manually stored maintenance and runtime intervals, as well as other data, an estimate can be made as to when a component in question, such as a drive or a bearing, is likely to fail. Service and maintenance work can advantageously be planned in an improved manner, taking this information into account. Overall, this makes it possible to reduce system maintenance costs and downtimes.
- the wear component is at least one of the following: Homogenizer mechanical seals, homogenizer mixing element, valve seals, pumps, agitator mechanical seals, agitator scrapers, heat exchangers.
- Optimized maintenance intervals can now be determined for the wear components mentioned, and an exchange of the components can preferably already be initiated when there is a sufficiently high probability that the component will fail in the near future.
- figure 1 shows a block diagram of a digitally networked mixing and/or homogenizing system 2 with a mixing and/or homogenizing device 4, a data network 28 and a remote control device 30.
- the mixing and/or homogenizing device 4 has a container 6 in which a mixing element 10 is arranged.
- the mixing element 10 is part of an agitator 8 , the mixing element 10 being connected to a drive device 12 .
- the drive device 12 serves to drive the mixing element 10, in particular to set it in rotation.
- the container 6 is also connected to a vacuum system 42 .
- a large number of pipelines are also arranged on the container 6 and form a pipeline system 14 .
- the pipeline system 14 or individual pipelines thereof are connected to valves 16 for influencing the flow through the pipeline system 14 .
- a homogenizer 38 is arranged below the container 6 in the figure. This is connected to the container 6 in a fluid-conducting manner.
- a transfer system 34 is also connected to the homogenizer 38 in a fluid-conducting manner.
- the mixing and/or homogenizing device 4 also has a sealing liquid system 36, a cover lift 44, a temperature control system 40 and a stationary cleaning device 32 on. The positioning of the components is in figure 1 shown only schematically.
- the mixing and/or homogenizing device 4 also has a control device 18 which has a processor 20 and a memory 22 .
- a sensor device 24 is connected to the control device 18 , which in turn has a large number of sensors that record measurement data on the individual components of the mixing and/or homogenizing device 4 .
- the control device 18 is also connected to a transmission device 26 in a data-conducting manner.
- the data transmission device 26 can be connected to a remote control device 30 via a data network 28 .
- data can be obtained from the mixing and/or homogenizing device 4 and data can be transmitted to the same.
- a block diagram of a digitally networked mixing and/or homogenizing system 2 is also shown in figure 2 shown.
- the digitally networked mixing and/or homogenizing system 2 has a mixing and/or homogenizing device 4 which is shown with a focus on the sensor device 24 and the control device 18 .
- Sensor device 24 initially has a large number of sensors, such as a temperature sensor 72, a pressure sensor 74, a flow sensor/flow sensor 76, a speed sensor 110, an end position sensor 78, a conductivity sensor 80, a level sensor 90 and a torque sensor 106.
- the measurement signal is converted into a digital signal by means of an analog/digital converter 112 and transmitted to the control device 18 by means of the data-carrying connection 46, which can be embodied as a Profibus, Ethernet, or direct connection.
- the data-carrying connection 46 which can be embodied as a Profibus, Ethernet, or direct connection.
- the control device 18 is connected to a data network 28 via a data transmission device 26 .
- the data network 28 has a switch 48, which is connected by means of an Ethernet connection 50 to the data transmission device 26 and thus to the mixing and/or homogenizing device 4.
- the remote control device 30 is connected to the data network 28 or the switch 48, which presently in three levels, an internal user level 56, an external user level 58 and an internal IT level 60, subdivided.
- the internal user level 56 has a PC client 62 and a mobile client 64 .
- the PC client 62 is connected to the switch 48 via an Ethernet connection 50 .
- the mobile client 64 is connected to the switch 48 via a wireless local area network (WLAN) 52 .
- the external user layer 58 has a PC client 62 and a mobile client 64 which are each connected to the switch 48 via a virtual private communication network (VPN) 54 .
- VPN virtual private communication network
- the internal IT level 60 has a server 66 which in turn has an Open Platform Communications (OPC) server 68 and an application server 70 .
- the server 66 is connected to the switch 48 via an Ethernet connection 50 .
- OPC Open Platform Communications
- FIG. 3 A schematic structure of a mixing and/or homogenizing device 4 is shown in figure 3 shown.
- the mixing and/or homogenizing device 4 has a container 6 in which mixing elements 10, 10' are arranged. These are part of an agitator 8 which additionally has a drive device 12 .
- the container 6 is connected to other components, for example a valve 16, by means of a pipe system 14.
- a homogenizer 38 is also arranged below the container 6 and is also connected to the pipeline system 14 and the container 6 in a fluid-conducting manner.
- the individual in the figure 3 Components shown have a variety of sensors, which are described in the following figures in each case related to assemblies.
- FIG. 4 So shows figure 4 first an individual depiction of the container 6.
- the container 6 has an image sensor 94 in its upper region for the optical detection of the interior of the container 6.
- FIG. An end position sensor 78 is also assigned to a container opening.
- the container 6 also has a temperature sensor 72 and a pressure sensor 74, a foam sensor 88, a filling level sensor 90 and an empty notification sensor 92.
- a weight sensor 108 is also assigned to the container 6.
- FIG 5 shows an agitator 8 with the mixing elements 10 and 10 ′ and the sensors arranged on the agitator 8 .
- bearing monitoring sensors 96 and wear sensors 98 are arranged, which enable early wear detection of a bearing.
- Torque sensors 106, speed sensors 110 and flushing device monitoring sensors 102 are also assigned to drive device 12 for detecting a non-explosive atmosphere.
- the drive device also has an end position sensor 78 , a wear sensor 98 and a temperature sensor 72 .
- a further temperature sensor 72, a bearing monitoring sensor 96 and a wear sensor 98 on a bearing of the mixing elements 10, 10' are arranged above the mixing elements 10, 10'.
- figure 6 shows the arrangement of sensors on the homogenizer 38.
- a pressure sensor 74 and a wear sensor 98 and a bearing monitoring sensor 96 are arranged in the upper area of the homogenizer 38.
- a torque sensor 106 and a speed sensor 110 are assigned to the drives M in each case.
- the temperature of the homogenizer 38 is also monitored by means of a temperature sensor 72 and has a flushing device monitoring sensor 102 for detecting a non-explosive atmosphere and a pressure sensor 74 .
- FIG 7 shows a sealing liquid system 36, which has a UV light sensor 100 in its reservoir 114, as well as a temperature sensor 72, a pressure sensor 74, a turbidity sensor/float sensor 82, a level sensor 90, and a low-level sensor 92.
- a Speed sensor 110 is arranged as well as a flow sensor/flow sensor 76 in the area of the discharge pipe.
- FIG 8 shows a stationary cleaning device 32, whereby in the context of the following description reference is primarily made to the arrangement of sensors on the stationary cleaning device 32.
- this has a temperature sensor 72, a pressure sensor 74, a conductivity sensor 80, a pH -Value sensor 86 and a foam sensor 88 on.
- Three pipeline sections are connected downstream of the connecting line arranged in the upper area, each of the pipeline sections having an end position sensor 78, a flow sensor/flow sensor 76 in an upper area and, in the area of the drive M, a bearing monitoring sensor 96, a wear sensor 98 and a speed sensor 110.
- each of the storage containers 114', 114", 114''' is assigned a filling level sensor 90, an empty notification sensor 92 and a weight sensor 108.
- figure 9 shows a transfer system 34, which is also described below with a focus on the sensor arrangement.
- One in the left area of the figure 9 arranged valve 16 is initially assigned an end position sensor 78.
- the line section related to the figure 9 extending from there to the right, has an empty notification sensor 92 .
- the transfer system 34 shown has further valves with end position sensors 78.
- the transfer system 34 has a temperature sensor 72, a pressure sensor 74 and a flow sensor/flow sensor 76 in an upper area, as well as a speed sensor 110 assigned to the drive M and a torque sensor in a pump area 106.
- the transmission G is also assigned a bearing monitoring sensor 96 and a wear sensor 98.
- figure 10 shows a temperature control system 40, which initially has a flow sensor/flow sensor 76 and a temperature sensor 72 in an upper area.
- a pressure sensor 74, a bearing monitoring sensor 96, a wear sensor 98, and a speed sensor 110 are assigned to a pump or its drive.
- a pressure sensor 74 and a fill level sensor 90 and a low-level sensor 92 are assigned to a pump or its drive.
- a temperature sensor 72 is also arranged in the center right area of the figure.
- FIG 11 Figure 12 shows a vacuum system 42, which will also be described below with a focus on sensor positioning.
- the vacuum system 42 initially has a pump with a drive M, with the drive M being assigned a bearing monitoring sensor 96, a wear sensor 98 and a speed sensor 110.
- a foam sensor 88 , a level sensor 90 , an empty notification sensor 92 , a temperature sensor 72 and a pressure sensor 74 are arranged in a vacuum container 116 .
- the vacuum system 42 also has an end position sensor 78 and a flow sensor/flow sensor 76 .
- figure 12 shows a lid lift 44, which has a drive M, which is monitored by a torque sensor 106.
- a bearing monitoring sensor 96 and a speed sensor 110 are also assigned to the transmission G.
- a plurality of end position sensors 78 and a wear sensor 98 are also assigned to the cover lift 44.
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Description
Die Erfindung betrifft ein digital vernetztes Misch- und/oder Homogenisieranlagensystem, insbesondere für Kosmetikprodukte, mit einer Misch- und/oder Homogenisiereinrichtung zum Mischen und Homogenisieren von Fluid, wobei die Misch- und/oder Homogenisiereinrichtung mindestens aufweist: einen Behälter zur Aufnahme von Fluid, ein Rührwerk, mit einem zumindest abschnittsweise in dem Behälter angeordneten Mischelement, sowie einer mit dem Mischelement verbundenen Antriebseinrichtung zum Antreiben des Mischelements, einen mit dem Behälter fluidleitend verbundenen Homogenisator mit mindestens einem Homogenisator-Mischelement und einer mit dem mindestens einen Homogenisator-Mischelement wirkverbundenen Homogenisator-Antriebseinheit, ein mit dem Homogenisator verbundenes Rohrleitungssystem, ein fluidleitend in dem Rohrleitungssystem angeordnetes, fernbetätigbares Ventil, eine Steuerungseinrichtung zur Steuerung der Antriebseinrichtung und/oder des Ventils, mit einem Prozessor und einem Speicher, eine mit der Steuerungseinrichtung datenleitend verbundene Sensoreinrichtung zur Ermittlung einer Messgröße und Umwandlung der Messgröße in ein Signal.The invention relates to a digitally networked mixing and/or homogenizing system, in particular for cosmetic products, with a mixing and/or homogenizing device for mixing and homogenizing fluid, the mixing and/or homogenizing device having at least: a container for receiving fluid, an agitator, with a mixing element arranged at least in sections in the container, as well as a drive device connected to the mixing element for driving the mixing element, a homogenizer connected to the container in a fluid-conducting manner with at least one homogenizer mixing element and a homogenizer operatively connected to the at least one homogenizer mixing element Drive unit, a pipeline system connected to the homogenizer, a remotely operable valve arranged in the pipeline system to conduct fluid, a control device for controlling the drive device and/or the valve, with a processor and a spoke r, a sensor device connected in a data-conducting manner to the control device for determining a measured variable and converting the measured variable into a signal.
Derartige Misch- und/oder Homogenisieranlagensysteme werden beispielsweise in der kosmetischen, pharmazeutischen oder chemischen Industrie bei der Herstellung von Cremes, Salben, Pasten oder dergleichen eingesetzt. Die Anlagensysteme weisen regelmäßig wenigstens einen Behälter auf, in dem das zu vermischende und zu verarbeitende Fluid aufgenommen ist. In einen solchen Behälter ist typischerweise ein Rührwerk eingebracht, welches ein Vermischen des Fluids ermöglicht. Mit dem Behälter fluidleitend verbunden ist typischerweise ein Homogenisator zum Homogenisieren des Fluids. Ferner weisen aus dem Stand der Technik bekannte Misch- und/oder Homogenisiereinrichtungen typischerweise eine Vielzahl von Leitungen und Ventilen zum Fluidtransport und zur Steuerung von Fluidflüssen auf. Ein betreffendes Misch- und/oder Homogenisieranlagensystem ist beispielsweise aus
Zur Sicherstellung einer hohen Verarbeitungsprozessqualität kommt der Erfassung von Messgrößen in den unterschiedlichen Komponenten eines Misch- und/oder Homogenisieranlagensystems eine besondere Bedeutung zu. Aus dem Stand der Technik vorbekannte Anlagensysteme weisen zu diesem Zweck typischerweise Sensoren auf, die datenleitend mit einer Steuerungseinrichtung verbunden sind. Unter anderem auf Basis der von den Sensoren ermittelten Messgrößen steuert die Steuerungseinrichtung eine Vielzahl von Aktuatoren an, etwa betreffend den Antrieb eines Mischelements, Ventilstellungen, und dergleichen.In order to ensure a high processing quality, the acquisition of measured variables in the different components of a mixing and/or homogenizing system is of particular importance. Plant systems previously known from the prior art typically have sensors for this purpose, which are connected to a control device in a data-conducting manner. Among other things, on the basis of the measured variables determined by the sensors, the control device controls a large number of actuators, for example relating to the drive of a mixing element, valve positions, and the like.
Nachteilig beim beschriebenen Stand der Technik wirkt sich allerdings aus, dass auf die Steuerungseinrichtung sowie die von der Sensoreinrichtung ermittelten Messgrößen nur sehr eingeschränkt und lediglich durch einen Bediener, der sich in unmittelbarer Nähe zu dem Misch- und/oder Homogenisieranlagensystem befindet, zugegriffen werden kann. Sowohl eine Betriebsdatenüberwachung, als auch eine Anpassung von Betriebsdaten ohne direkten Kontakt zu dem System ist somit nicht möglich. Auch wirkt sich nachteilig aus, dass lediglich eine eng begrenzte Anzahl von Messgrößen erfasst werden und Lebenszyklusinformationen und Ausfallwahrscheinlichkeiten einzelner Komponenten nicht oder nur unter größter Mühe ermittelt werden können.A disadvantage of the described prior art, however, is that the control device and the measured variables determined by the sensor device can only be accessed to a very limited extent and only by an operator who is in the immediate vicinity of the mixing and/or homogenizing system. It is therefore not possible to monitor operating data or to adjust operating data without direct contact with the system. Another disadvantage is that only a very limited number of measured variables are recorded and life cycle information and failure probabilities of individual components cannot be determined or can only be determined with great difficulty.
Vor diesem Hintergrund lag der Erfindung die Aufgabe zugrunde, ein Misch- und/oder Homogenisieranlagensystem dahingehend weiterzubilden, dass die im Stand der Technik aufgefundenen Nachteile möglichst weitgehend behoben werden. Insbesondere war ein Misch- und/oder Homogenisieranlagensystem anzugeben, welches eine verbesserte Zustandsüberwachung wesentlicher Betriebskomponenten erlaubt und gleichzeitig einen weitestgehend ortsungebundenen Zugriff auf die Komponenten einer solchen Anlage ermöglicht.Against this background, the invention was based on the object of further developing a mixing and/or homogenizing plant system in such a way that the disadvantages found in the prior art are eliminated as far as possible. In particular, a mixing and/or homogenizing plant system was to be specified which allows improved status monitoring of essential operating components and at the same time enables largely location-independent access to the components of such a plant.
Erfindungsgemäß wird die Aufgabe bei einem Misch- und/oder Homogenisieranlagensystem der eingangs genannten Art gelöst durch eine mit Steuerungseinrichtung datenleitend verbundenen Datenübertragungseinrichtung, ein mit der Datenübertragungseinrichtung datenleitend verbindbares Datennetzwerk, sowie eine mit dem Datennetzwerk datenleitend verbindbare Fernsteuerungseinrichtung, die dazu eingerichtet ist, Daten mittels des Datennetzwerks an die Datenübertragungseinrichtung zu senden und/oder von dieser zu empfangen, wobei die Fernsteuerungseinrichtung dazu eingerichtet ist, das Folgende auszuführen: Auswertung von Sensordaten und/oder Prozessinformationen zur vorausschauenden Wartung einer Verschleißkomponente der Misch- und Homogenisieranlage.According to the invention, the object is achieved in a mixing and/or homogenizing system of the type mentioned at the outset by a data transmission device connected to the control device in a data-conducting manner, a data network that can be connected to the data transmission device in a data-conducting manner, and a remote control device that can be connected to the data network in a data-conducting manner and is set up to transmit data using the To send data network to the data transmission device and / or to receive it, the remote control device being set up to perform the following: evaluation of sensor data and / or process information for predictive maintenance of a wear component of the mixing and homogenizing system.
Ein solches vorgeschlagenes digital vernetztes Misch- und/oder Homogenisieranlagensystem ermöglicht es auf einfache Weise, von nahezu jedem beliebigen Ort Daten, insbesondere Betriebsdaten und dergleichen, von einer Misch- und/oder Homogenisiereinrichtung zu empfangen, auszuwerten, und zu überwachen. Gleichzeitig kann auf dieselbe Weise nahezu ortsunabhängig insbesondere auf die Steuerungseinrichtung einer solchen Misch- und/oder Homogenisiereinrichtung von einem autorisierten Benutzer zugegriffen werden, um etwa den Misch- und/oder Homogenisierprozess zu beeinflussen und zu optimieren. Ein Bediener oder Wartungstechniker muss nicht länger persönlich zum Zwecke der Betriebsdatenüberwachung und Steuerungsanpassung in den Nahbereich einer Anlage treten und sich vor Ort Zugang zu der Steuerungseinrichtung verschaffen. Insgesamt lassen sich somit nicht nur Betriebs- und Wartungskosten sparen, sondern es lässt sich ferner schneller und kostengünstiger auf den Betrieb eines solchen Misch- und/oder Homogenisieranlagensystems Einfluss nehmen.Such a proposed digitally networked mixing and/or homogenizing plant system makes it possible in a simple manner to transfer data, in particular operating data and the like, from a mixing and/or receiving, evaluating and monitoring the homogenizing device. At the same time, an authorized user can access the control device of such a mixing and/or homogenizing device almost independently of location in order to influence and optimize the mixing and/or homogenizing process. An operator or maintenance technician no longer has to personally go into the vicinity of a plant and gain on-site access to the control device for the purpose of operational data monitoring and control adjustment. Overall, not only can operating and maintenance costs be saved, but the operation of such a mixing and/or homogenizing system can also be influenced more quickly and cost-effectively.
Die Erfindung wird dadurch weitergebildet, dass die Misch- und/oder Homogenisiereinrichtung eine, mehrere, oder sämtliche der folgenden Komponenten aufweist: ortsgebundene Reinigungseinrichtung, Transfersystem, Sperrflüssigkeitssystem, Temperiersystem, Vakuumsystem, Deckellift.The invention is further developed in that the mixing and/or homogenizing device has one, several, or all of the following components: stationary cleaning device, transfer system, sealing liquid system, temperature control system, vacuum system, lid lift.
Die beschriebenen Komponenten bzw. Baugruppen haben sich als besonders vorteilhaft zur Durchführung industrieller Misch- und/oder Homogenisieranwendungen erwiesen, bei denen bei hoher Verarbeitungsqualität große Fluidmengen verarbeitet werden sollen.The components or assemblies described have proven to be particularly advantageous for carrying out industrial mixing and/or homogenizing applications in which large quantities of fluid are to be processed with high processing quality.
Gemäß einer weiteren bevorzugten Ausführungsform ist die datenleitende Verbindung zwischen der Sensoreinrichtung und der Steuerungseinrichtung als wenigstens einer der folgenden ausgebildet: Profibus, Ethernet, Direktverbindung. Alle drei Arten der Datenverbindung haben sich als zuverlässige, schnelle, und einen ausreichenden Datendurchsatz aufweisende datenleitende Verbindungen herausgestellt, insbesondere zur Übermittlung der mehreren Sensordaten von der Sensoreinrichtung an die Steuerungseinrichtung. Die Sensordaten können somit im Wesentlichen in Echtzeit an die Steuerungseinrichtung übertragen werden.According to a further preferred embodiment, the data-carrying connection between the sensor device and the control device is designed as at least one of the following: Profibus, Ethernet, direct connection. All three types of data connection have proven to be reliable, fast data-carrying connections and have a sufficient data throughput, in particular for the transmission of the multiple sensor data from the sensor device to the control device. The sensor data can thus be transmitted to the control device essentially in real time.
Weiterhin bevorzugt weist die Datenübertragungseinrichtung einen Switch auf. Ferner ist bevorzugt, dass das Datennetzwerk als eines der folgenden ausgebildet ist: Ethernet, drahtloses lokales Netzwerk, virtuelles privates Kommunikationsnetz. Je nach Anwendungsbereich, wenn etwa eine kabelgebundene Verbindung zu einer Misch- und/oder Homogenisiereinrichtung besteht, kann eine einen hohen Datendurchsatz aufweisende Ethernetverbindung vorteilhaft sein. Im unmittelbaren Umfeld einer Misch- und/oder Homogenisiereinrichtung kann darüber hinaus für einen besonders flexiblen Zugriff das Datennetzwerk als drahtloses lokales Netzwerk ausgebildet sein. Einer hohen Sicherheitsanforderung genügende Verbindung von entfernten Orten kann im Wesentlichen in Echtzeit über ein virtuelles privates Kommunikationsnetz (VPN) hergestellt werden.Furthermore, the data transmission device preferably has a switch. Furthermore, it is preferred that the data network is designed as one of the following: Ethernet, wireless local area network, virtual private communication network. Depending on the area of application, for example if there is a wired connection to a mixing and/or homogenizing device, an Ethernet connection with a high data throughput can be advantageous. In the immediate vicinity of a mixing and/or homogenizing device, the data network can also be designed as a wireless local area network for particularly flexible access. a high one Security-compliant connection from remote locations can be established in essentially real-time via a Virtual Private Communications Network (VPN).
Gemäß einer bevorzugten Weiterbildung weist die Fernsteuerungseinrichtung wenigstens eine der folgenden Benutzerebenen auf: interne Anwenderebene, externe Anwenderebene, interne IT-Ebene. Mittels der Gliederung der Fernsteuerungseinrichtung in unterschiedliche Benutzerebenen lässt sich der Umfang der Zugriffsberechtigung anpassen, ob also etwa einen bestimmten Benutzer lediglich gestattet ist, eine Auswahl von Betriebsparametern, wie Sensordaten einzusehen, und es etwa einen weiteren Benutzer zusätzlich gestattet ist, Einfluss zu nehmen auf die Steuerung des Misch- und/oder Homogenisieranlagensystems. Es kann ferner danach differenziert werden, an welchem Ort sich der Benutzer aufhält, ob er sich also in etwa in unmittelbarer Nähe zu der Misch- und/oder Homogenisiereinrichtung befindet, in derselben Herstellungsumgebung (Fabrik), im Anlagenherstellerunternehmen, oder an einem beliebigen, davon entfernten Ort.According to a preferred development, the remote control device has at least one of the following user levels: internal user level, external user level, internal IT level. By dividing the remote control device into different user levels, the scope of the access authorization can be adjusted, i.e. whether a specific user is only allowed to view a selection of operating parameters, such as sensor data, and whether another user is also allowed to influence the Control of the mixing and/or homogenizing plant system. It can also be differentiated according to where the user is located, i.e. whether he is in close proximity to the mixing and/or homogenizing device, in the same manufacturing environment (factory), in the plant manufacturing company, or at any one of these distant place.
Die Erfindung wird dadurch weitergebildet, dass die interne Anwenderebene und/oder die externe Anwenderebene einen PC-Client und/oder einen Mobil-Client aufweisen. Somit ist es sowohl innerhalb der internen Anwenderebene als auch innerhalb der externen Anwenderebene möglich, eine Datenverbindung sowohl mittels eines Personalcomputers und einem auf diesem ausgeführten Clienten vorzunehmen, als auch mittels eines mobilen Endgerätes, welches ebenfalls einen betreffenden Clienten ausführt.The invention is further developed in that the internal user level and/or the external user level have a PC client and/or a mobile client. It is thus possible both within the internal user level and within the external user level to set up a data connection both using a personal computer and a client running on it, and using a mobile terminal device which also runs a relevant client.
Eine weitere alternativ bevorzugte Ausführungsform zeichnet sich dadurch aus, dass die interne Anwenderebene über ein lokales Netzwerk, insbesondere Ethernet oder ein drahtloses lokales Netzwerk, mit der Datenübertragungseinrichtung verbunden ist, und/oder die externe Anwenderebene über ein virtuelles privates Kommunikationsnetz mit der Datenübertragungseinrichtung verbunden ist.Another alternative preferred embodiment is characterized in that the internal user level is connected to the data transmission device via a local network, in particular Ethernet or a wireless local network, and/or the external user level is connected to the data transmission device via a virtual private communication network.
Im Hinblick auf die interne Anwenderebene, wird vorzugsweise auf lokale Netzwerktypen bzw. Netzwerkstandards zurückgegriffen. Die Anbindung eines stationären bzw. teilstationären Personalcomputers bietet sich dabei mittels einer Ethernetverbindung an, welche eine sichere und breitbandige Anbindung ermöglicht. Der Mobil-Client wird vorzugsweise über ein lokales drahtloses Netzwerk (WLAN) angebunden, wobei auch hier hohe Datenraten bei einer hohen Netzwerksicherheit erreicht werden können. Die Anbindung der externen Anwenderebene erfolgt vorzugsweise über ein virtuelles privates Kommunikationsnetz, welches quasi ortsungebunden eine sichere Datenübertragung mit der Datenübertragungseinrichtung gewährleistet.With regard to the internal user level, local network types or network standards are preferably used. The connection of a stationary or semi-stationary personal computer is possible by means of an Ethernet connection, which enables a secure and broadband connection. The mobile client is preferably connected via a wireless local area network (WLAN), with high data rates and high network security being able to be achieved here as well. The external user level is preferably connected via a virtual private Communications network, which ensures secure data transmission with the data transmission device, virtually independent of location.
Die Erfindung wird dadurch weitergebildet, dass die interne IT-Ebene wenigstens einen Server aufweist, welcher insbesondere einen Schnittstellenserver, insbesondere einen Open Platform Communications (OPC)-Server, aufweist und/oder einen Applikationsserver.The invention is further developed in that the internal IT level has at least one server, which in particular has an interface server, in particular an Open Platform Communications (OPC) server, and/or an application server.
Der Applikationsserver dient im Wesentlichen als Server für die PC-Clienten sowie die mobilen Clienten der internen sowie externen Anwenderebene. Mittels des OPC-Servers lassen sich die Betriebsdaten, wie insbesondere die Sensordaten, einer Misch- und/oder Homogenisiereinrichtung erfassen, aufbereiten und auswerten und es kann gleichzeitig bedarfsweise auf die Steuerungseinrichtung Einfluss genommen werden.The application server essentially serves as a server for the PC clients and the mobile clients of the internal and external user level. The operating data, such as in particular the sensor data, of a mixing and/or homogenizing device can be recorded, processed and evaluated by means of the OPC server, and at the same time the control device can be influenced as required.
Vorzugsweise ist die interne IT-Ebene über ein lokales Netzwerk, insbesondere Ethernet, mit der Datenübertragungseinrichtung verbunden. Die Ethernetverbindung stellt dabei eine breitbandige und sichere Verbindungsart dar.The internal IT level is preferably connected to the data transmission device via a local network, in particular Ethernet. The Ethernet connection represents a broadband and secure connection type.
Gemäß einer bevorzugten Weiterbildung weist die Sensoreinrichtung mindestens einen der folgenden Sensoren auf: Temperatursensor, Drucksensor, Durchflusssensor/Strömungssensor, Endlagensensor, Leitfähigkeitssensor, Trübungssensor/Schwebekörpersensor, Viskositätssensor, pH-Wert-Sensor, Schaumsensor, Füllstandsensor, Leermeldungssensor, Bildsensor, insbesondere Videokamera, Lagerüberwachungssensor, Verschleißsensor, UV-Licht-Sensor, Spüleinrichtungs-Überwachungssensor zur Detektion einer nicht explosionsfähigen Atmosphäre, Wassersensor, Drehmomentsensor, Gewichtsensor, Drehzahlsensor.According to a preferred development, the sensor device has at least one of the following sensors: temperature sensor, pressure sensor, flow sensor/flow sensor, end position sensor, conductivity sensor, turbidity sensor/float sensor, viscosity sensor, pH value sensor, foam sensor, filling level sensor, empty notification sensor, image sensor, in particular video camera, storage monitoring sensor , wear sensor, UV light sensor, flushing device monitoring sensor for detecting a non-explosive atmosphere, water sensor, torque sensor, weight sensor, speed sensor.
Die genannten Sensoren und Sensortypen haben sich als besonders geeignet und vorteilhaft für die Verwendung in einer Misch- und/oder Homogenisiereinrichtung zur Überwachung der unterschiedlichsten Betriebszustände und Bauteilpositionen sowie der Fluidzustände erwiesen.The sensors and sensor types mentioned have proven to be particularly suitable and advantageous for use in a mixing and/or homogenizing device for monitoring a wide variety of operating states and component positions as well as the fluid states.
Darüber hinaus sensiert der Endlagensensor vorzugsweise die Endlage mindestens eines der folgenden: Ventilstellung, Mannlochstellung, Deckelposition, Koppelbodeninstallation. Die ordnungsgemäße Positionierung bzw. ein ordnungsgemäßer Verschluss von Betriebs- und Wartungsöffnungen der Misch- und/oder Homogenisiereinrichtung kann damit sichergestellt werden.In addition, the end position sensor preferably senses the end position of at least one of the following: valve position, manhole position, cover position, coupling floor installation. The correct positioning or a correct closure of operating and maintenance openings of the mixing and/or homogenizing device can thus be ensured.
Der Lagerüberwachungssensor ist vorzugsweise als Schwingungssensor ausgebildet. Eine Detektion von an einem Lager auftretenden Schwingungen hat sich als besonders geeignet dazu erwiesen, einen Lagerzustand zu überwachen. Eine Zunahme von Vibrationen bzw. Schwingungen an einem Lager lässt Rückschlüsse auf den Lagerverschleiß zu, und ermöglicht ferner die Durchführung von präventiven Wartungsereignissen, wenn aufgrund beispielsweise der ermittelten Schwingungen absehbar ist, dass ein Lager in naher Zukunft versagen wird und auszutauschen ist.The bearing monitoring sensor is preferably designed as a vibration sensor. A detection of vibrations occurring in a bearing has proven to be particularly suitable for monitoring a bearing condition. An increase in vibrations or oscillations in a bearing allows conclusions to be drawn about bearing wear and also enables preventive maintenance events to be carried out if, for example, the vibrations determined indicate that a bearing will fail in the near future and needs to be replaced.
Gemäß einer bevorzugten Ausführungsform weist der Behälter einen, mehrere oder sämtliche der folgenden Sensoren auf: Temperatursensor, Drucksensor, Endlagensensor, Schaumsensor, Füllstandsensor, Leermeldungssensor, Bildsensor, Gewichtsensor. Die genannten Sensoren haben sich dabei als vorzugswürdig erwiesen, eine umfassende und genaue Überwachung der in dem Behälter und im unmittelbaren Umfeld des Behälters anlaufenden Vorgänge zu gewährleisten.According to a preferred embodiment, the container has one, several or all of the following sensors: temperature sensor, pressure sensor, end position sensor, foam sensor, filling level sensor, empty notification sensor, image sensor, weight sensor. The sensors mentioned have proven to be preferable to ensure comprehensive and accurate monitoring of the processes starting in the container and in the immediate vicinity of the container.
Weiterhin bevorzugt weist das Rührwerk einen, mehrere oder sämtlich der folgenden Sensoren auf: Lagerüberwachungssensor, Verschleißsensor, Spüleinrichtungs-Überwachungssensor zur Detektion einer nicht explosionsfähigen Atmosphäre, Drehzahlsensor, Drehmomentsensor.The agitator also preferably has one, several or all of the following sensors: bearing monitoring sensor, wear sensor, flushing device monitoring sensor for detecting a non-explosive atmosphere, speed sensor, torque sensor.
Mittels des Lagerüberwachungssensors und des Verschleißsensors können auch hier vor dem unmittelbaren Versagen bzw. Ausfallen einzelner Komponenten Rückschlüsse auf ein bevorstehendes Ausfall- bzw. Wartungsereignis gezogen werden.By means of the bearing monitoring sensor and the wear sensor, it is also possible here to draw conclusions about an imminent failure or maintenance event before the immediate failure or failure of individual components.
Vorzugsweise weist der Homogenisator einen, mehrere oder sämtliche der folgenden Sensoren auf: Drucksensor, Lagerüberwachungssensor, Verschleißsensor, Antriebsüberwachungssensor einer Spüleinrichtung, Drehzahlsensor, Drehmomentsensor. Auch die hier beschriebenen Sensoren ermöglichen eine umfangreiche Zustandsüberwachung und eine Früherkennung eventueller Ausfallereignisse zur Reduzierung von Ausfallzeiten.The homogenizer preferably has one, several or all of the following sensors: pressure sensor, bearing monitoring sensor, wear sensor, drive monitoring sensor of a flushing device, speed sensor, torque sensor. The sensors described here also enable extensive condition monitoring and early detection of possible failure events to reduce downtimes.
Gemäß einer weiteren bevorzugten Ausführungsform weist die Sensoreinrichtung wenigstens einen Analog-Digital-Umsetzer zur Umwandlung eines analogen Sensorsignals in ein digitales Sensorsignal auf.According to a further preferred embodiment, the sensor device has at least one analog/digital converter for converting an analog sensor signal into a digital sensor signal.
Die Erfindung wird dadurch weitergebildet, dass die Fernsteuerungseinrichtung dazu eingerichtet ist, wenigstens eines der folgenden auszuführen: Auswertung von Sensordaten und Ermittlung von Prozessinformationen, insbesondere in Echtzeit, Archivierung von Sensordaten und/oder Prozessinformationen.The invention is further developed in that the remote control device is set up to carry out at least one of the following: evaluation of sensor data and determination of process information, in particular in real time, Archiving of sensor data and/or process information.
Im Rahmen der Auswertung von Sensordaten und der Ermittlung von Prozessinformationen werden dem Bediener vorzugsweise eine Vielzahl von Sensordaten und Prozessinformationen zur Anzeige gebracht. Dieser kann sich sodann ein umfangreiches Gesamtbild und auch detaillierte Informationen über einzelne Anlagebereiche und Verfahrensschritte verschaffen. Ferner ist bevorzugt, dass die Auswertung von Sensordaten mittels statistischer Methoden erfolgt und Vergangenheitsdaten mit den in Echtzeit ermittelten Sensordaten verglichen und korreliert werden, insbesondere zur Früherkennung von Fehlentwicklungen und Wartungsereignissen.As part of the evaluation of sensor data and the determination of process information, the operator is preferably shown a large number of sensor data and process information. He can then obtain a comprehensive overall picture and also detailed information about individual plant areas and process steps. Furthermore, it is preferred that the evaluation of sensor data takes place using statistical methods and that historical data is compared and correlated with the sensor data determined in real time, in particular for the early detection of undesirable developments and maintenance events.
Hierbei ist vorgesehen, dass Sensordaten und/oder Prozessinformationen ferner zu vorausschauenden Wartung von Verschleißkomponenten verwendet werden. Auf Basis statistischen Auswertungen, manuell hinterlegter Wartungs- und Laufzeitintervalle, sowie anderer Daten, kann eine Abschätzung erfolgen, wann eine betreffende Komponente, etwa ein Antrieb oder ein Lager, mit einer gewissen Wahrscheinlichkeit ausfallen wird. Service- und Wartungsarbeiten können unter Berücksichtigung dieser Informationen auf vorteilhafte Weise verbessert geplant werden. Hierdurch ist es insgesamt möglich, Anlagen-Wartungskosten und die Ausfallzeiten zu reduzieren.It is provided here that sensor data and/or process information is also used for predictive maintenance of wearing components. Based on statistical evaluations, manually stored maintenance and runtime intervals, as well as other data, an estimate can be made as to when a component in question, such as a drive or a bearing, is likely to fail. Service and maintenance work can advantageously be planned in an improved manner, taking this information into account. Overall, this makes it possible to reduce system maintenance costs and downtimes.
Dabei ist bevorzugt, dass die Verschleißkomponente wenigstens eine der folgenden ist:
Gleitringdichtungen des Homogenisators, Homogenisator-Mischelement, Ventildichtungen, Pumpen, Gleitringdichtungen des Rührwerks, Abstreifer des Rührwerks, Wärmetauscher. Für die genannten Verschleißkomponenten können nunmehr optimierte Wartungsintervalle ermittelt werden und vorzugsweise bereits dann ein Austausch der Komponenten eingeleitet werden, wenn mit einer hinreichend hohen Wahrscheinlichkeit zu erwarten ist, dass die Komponente zeitnah ausfallen wird.It is preferred that the wear component is at least one of the following:
Homogenizer mechanical seals, homogenizer mixing element, valve seals, pumps, agitator mechanical seals, agitator scrapers, heat exchangers. Optimized maintenance intervals can now be determined for the wear components mentioned, and an exchange of the components can preferably already be initiated when there is a sufficiently high probability that the component will fail in the near future.
Die Erfindung wird nachfolgend anhand eines bevorzugten Ausführungsbeispiels unter Bezugnahme auf die beigefügten Figuren näher beschrieben.The invention is described in more detail below using a preferred exemplary embodiment with reference to the attached figures.
Im Einzelnen zeigen:
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Fig. 1 ein erstes Ausführungsbeispiel eines erfindungsgemäßen digital vernetzten Misch- und/oder Homogenisieranlagensystems in einer Blockdarstellung; -
Fig. 2 das Ausführungsbeispiel eines erfindungsgemäßen digital vernetzten Misch- und/oder Homogenisieranlagensystems gemäßFig. 1 in einer erweiterten Blockdarstellung; -
Fig. 3 ein Ausführungsbeispiel einer Misch- und/oder Homogenisiereinrichtung in einer schematischen Darstellung; -
Fig. 4 einen Behälter einer erfindungsgemäßen Misch- und/oder Homogenisiereinrichtung in einer schematischen Darstellung; -
Fig. 5 ein Rührwerk einer erfindungsgemäßen Misch- und/oder Homogenisiereinrichtung in einer schematischen Darstellung; und -
Fign. 6 weitere Komponenten und Baugruppen einer erfindungsgemäßen Misch- und/oder Homogenisiereinrichtung in schematischen Darstellungen.bis 12
-
1 a first exemplary embodiment of a digitally networked mixing and/or homogenizing system according to the invention in a block diagram; -
2 the exemplary embodiment of a digitally networked mixing and/or homogenizing system according to the invention1 in an expanded block representation; -
3 an embodiment of a mixing and / or homogenizing device in a schematic representation; -
4 a container of a mixing and/or homogenizing device according to the invention in a schematic representation; -
figure 5 an agitator of a mixing and/or homogenizing device according to the invention in a schematic representation; and -
Figs. 6 to 12 further components and assemblies of a mixing and/or homogenizing device according to the invention in schematic representations.
Die Misch- und/oder Homogenisiereinrichtung 4 weist einen Behälter 6 auf, in welchem ein Mischelement 10 angeordnet ist. Das Mischelement 10 ist Teil eines Rührwerkes 8, wobei das Mischelement 10 mit einer Antriebseinrichtung 12 verbunden ist. Die Antriebseinrichtung 12 dient dem Antrieb des Mischelements 10, insbesondere dem in Rotation versetzen desselben. Der Behälter 6 ist ferner mit einem Vakuumsystem 42 verbunden. An dem Behälter 6 sind weiterhin eine Vielzahl von Rohrleitungen angeordnet, die ein Rohrleitungssystem 14 ausbilden. Das Rohrleitungssystem 14 bzw. einzelne Rohrleitungen desselben sind mit Ventilen 16 zur Beeinflussung des Durchflusses durch das Rohrleitungssystem 14 verbunden. In der Figur unterhalb des Behälters 6 ist ein Homogenisator 38 angeordnet. Dieser fluidleitend mit dem Behälter 6 verbunden. Fluidleitend mit dem Homogenisator 38 ist ferner ein Transfersystem 34 verbunden. Die Misch- und/oder Homogenisiereinrichtung 4 weist darüber hinaus ein Sperrflüssigkeitssystem 36, einen Deckellift 44, ein Temperiersystem 40 sowie eine ortsgebundene Reinigungseinrichtung 32 auf. Die Positionierung der Komponenten ist in
Die Misch- und/oder Homogenisiereinrichtung 4 weist darüber hinaus eine Steuerungseinrichtung 18 auf, die einen Prozessor 20 sowie einen Speicher 22 aufweist. Mit der Steuerungseinrichtung 18 ist eine Sensoreinrichtung 24 verbunden, welche ihrerseits eine Vielzahl von Sensoren aufweist, die an den einzelnen Komponenten der Misch- und/oder Homogenisiereinrichtung 4 Messdaten erfassen.The mixing and/or homogenizing
Die Steuerungseinrichtung 18 ist ferner datenleitend mit einer Übertragungseinrichtung 26 verbunden. Die Datenübertragungseinrichtung 26 ist über ein Datennetzwerk 28 mit einer Fernsteuerungseinrichtung 30 verbindbar. Mittels der Fernsteuerungseinrichtung 30 können Daten von der Misch- und/oder Homogenisiereinrichtung 4 bezogen werden und Daten an selbige übermittelt werden.The
Ein Blockschaltbild eines digital vernetzten Misch- und/oder Homogenisieranlagensystems 2 ist ferner in
Die Steuerungseinrichtung 18 ist über eine Datenübertragungseinrichtung 26 mit einem Datennetzwerk 28 verbunden. Vorliegend weist das Datennetzwerk 28 einen Switch 48 auf, der mittels einer Ethernetverbindung 50 mit der Datenübertragungseinrichtung 26 verbunden ist und somit mit der Misch- und/oder Homogenisiereinrichtung 4. Mit dem Datennetzwerk 28 bzw. dem Switch 48 ist die Fernsteuerungseinrichtung 30 verbunden, die sich vorliegend in drei Ebenen, eine interne Anwenderebene 56, eine externe Anwenderebene 58 sowie eine interne IT-Ebene 60, untergliedert.The
Die interne Anwenderebene 56 weist einen PC-Client 62 sowie einen Mobil-Client 64 auf. Der PC-Client 62 ist mittels einer Ethernetverbindung 50 mit dem Switch 48 verbunden.The
Der Mobil-Client 64 ist mittels eines drahtlosen lokalen Netzwerkes (WLAN) 52 mit dem Switch 48 verbunden. Die externe Anwenderebene 58 weist einen PC-Client 62 sowie einen Mobil-Client 64 auf, welche jeweils über ein virtuelles privates Kommunikationsnetz (VPN) 54 mit dem Switch 48 verbunden sind.The
Die interne IT-Ebene 60 weist einen Server 66 auf, welcher wiederum einen Open Platform Communications (OPC)-Server 68 sowie einen Applikationsserver 70 aufweist. Der Server 66 ist mittels einer Ethernetverbindung 50 mit dem Switch 48 verbunden.The
Ein schematischer Aufbau einer Misch- und/oder Homogenisiereinrichtung 4 ist in
So zeigt
- 22
- Digital vernetztes Misch- und/oder HomogenisieranlagensystemDigitally networked mixing and/or homogenizing system
- 44
- Misch- und/oder HomogenisiereinrichtungMixing and/or homogenizing device
- 66
- Behältercontainer
- 88th
- Rührwerkagitator
- 10, 10'10, 10'
- Mischelementmixing element
- 1212
- Antriebseinrichtungdrive device
- 1414
- Rohrleitungssystempiping system
- 1616
- VentilValve
- 1818
- Steuerungseinrichtungcontrol device
- 2020
- Prozessorprocessor
- 2222
- SpeicherStorage
- 2424
- Sensoreinrichtungsensor device
- 2626
- Datenübertragungseinrichtungdata transmission facility
- 2828
- Datennetzwerkdata network
- 3030
- Fernsteuerungseinrichtungremote control device
- 3232
- ortsgebundene Reinigungseinrichtungon-site cleaning facility
- 3434
- Transfersystemtransfer system
- 3636
- Sperrflüssigkeitssystembarrier fluid system
- 3737
- Homogenisator-MischelementHomogenizer mixing element
- 3838
- Homogenisatorhomogenizer
- 3939
- Homogenisator-AntriebseinheitHomogenizer drive unit
- 4040
- Temperiersystemtemperature control system
- 4242
- Vakuumsystemvacuum system
- 4444
- Deckelliftlid lift
- 4646
- datenleitende Verbindung zwischen Sensoreinrichtung und Steuerungseinrichtungdata-conducting connection between sensor device and control device
- 4848
- Switchswitches
- 5050
- Ethernetethernet
- 5252
- drahtloses lokales Netzwerk (W-LAN)wireless local area network (W-LAN)
- 5454
- virtuelles privates Kommunikationsnetz (VPN)virtual private communication network (VPN)
- 5656
- interne Anwenderebeneinternal user level
- 5858
- externe Anwenderebeneexternal user level
- 6060
- interne IT-Ebeneinternal IT level
- 6262
- PC-ClientPC client
- 6464
- Mobil-Clientmobile client
- 6666
- Serverserver
- 6868
- Open Platform Communications (OPC)-ServerOpen Platform Communications (OPC) server
- 7070
- Applikationsserverapplication server
- 7272
- Temperatursensortemperature sensor
- 7474
- Drucksensorpressure sensor
- 7676
- Durchflusssensor/StrömungssensorFlow sensor/flow sensor
- 7878
- Endlagensensorend position sensor
- 8080
- Leitfähigkeitssensorconductivity sensor
- 8282
- Trübungssensor/SchwebekörpersensorTurbidity sensor/float sensor
- 8484
- Viskositätssensorviscosity sensor
- 8686
- pH-Wert-SensorpH sensor
- 8888
- Schaumsensorfoam sensor
- 9090
- Füllstandssensorlevel sensor
- 9292
- Leermeldungssensorlow level sensor
- 9494
- Bildsensor, insbesondere VideokameraImage sensor, in particular video camera
- 9696
- LagerüberwachungssensorStock monitoring sensor
- 9898
- Verschleißsensorwear sensor
- 100100
- UV-Licht-SensorUV light sensor
- 102102
- Spüleinrichtungs-Überwachungssensor zur Detektion einer nicht explosionsfähigen AtmosphäreFlushing device monitoring sensor for the detection of a non-explosive atmosphere
- 104104
- Wassersensorwater sensor
- 106106
- Drehmomentsensortorque sensor
- 108108
- Gewichtssensorweight sensor
- 110110
- Drehzahlsensorspeed sensor
- 112112
- Analog-Digital-UmsetzerAnalog to digital converter
- 114, 114' 114", 114‴114, 114' 114", 114‴
- Vorratsbehälterreservoir
- 116116
- Vakuumbehältnisvacuum container
Claims (15)
- Digitally crosslinked mixing and/or homogenisation system (2), in particular for cosmetic products, having:- a mixing and/or homogenisation device (4) for mixing and homogenising fluid, the mixing and/or homogenisation device (4) having at least:- a container (6) for receiving fluid,- an agitator (8) with a mixing element (10, 10') which is disposed at least in portions in the container, and also an actuation device (12) which is in operational connection with the mixing element (10, 10') for actuating the mixing element (10, 10'),- a homogeniser (38) which is connected in a fluid-conducting manner to the container (6) and has at least one homogeniser mixing element (37) and has a homogeniser actuation unit (39) which is in operational connection with the at least one homogeniser mixing element (37),- a pipe system (14) which is connected to the homogeniser (38),- a remotely actuatable valve (16) which is disposed in a fluid-conducting manner in the pipe system (14),- a control device (18) for controlling the actuation device (12) and/or the valve (16),- a sensor device (24), which is connected in a data-conducting manner to the control device (18), for detecting a measuring value and converting the measuring value into a signal,characterised in that the control device has a processor and a memory, the mixing and/or homogenisation device (4) having furthermore the following features:- a data transmission device (26) which is connected in a data-conducting manner to the control device (18),- a data network (28) which can be connected in a data-conducting manner to the data transmission device (26), and also- a remote control device (30), which can be connected in a data-conducting manner to the data network (28) and which is fitted to send data by means of the data network (28) to the data transmission device (26) and/or to receive data from the latter, the remote control device (30) being fitted to implement the following: evaluating sensor data and/or process information for prospective maintenance of a wear component of the mixing and homogenisation unit.
- System (2) according to claim 1,
characterised in that the mixing and/or homogenisation device (4) has one, several or all of the following components:- fixed cleaning device (32),- transfer system (34),- sealing fluid system (36),- temperature-control system (40),- vacuum system (42),- cover lift (44). - System (2) according to one of the preceding claims,
characterised in that the data-conducting connection (46) between the sensor device (24) and the control device (18) is configured as at least one of the following:- profile bus,- ethernet (50),- direct connection. - System (2) according to one of the preceding claims,
characterised in that the data transmission device (26) has a switch (48). - System (2) according to one of the preceding claims,
characterised in that the data network (28) is configured as one of the following:- ethernet (50),- wireless local network (52),- virtual private communication network (54). - System (2) according to one of the preceding claims,
characterised in that the remote control device (30) has at least one of the following user levels:- internal user level (56),- external user level (58),- internal IT level (60). - System (2) according to claim 6,
characterised in that the internal user level (56) and/or the external user level (58) have a PC client (62) and/or a mobile client (64). - System (2) according to one of claims 6 to 7,
characterised in that the internal user level (56) is connected via a local network, in particular ethernet (50) or wireless local network (52), to the data transmission device (26), and/or the external user level (58) is connected via a virtual private communication network (54) to the data transmission device (26). - System (2) according to one of claims 6 to 8,
characterised in that the internal IT level (60) has at least one server (66), which has in particular an interface server, in particular an Open Platform Communications (OPC) server (68), and/or an application server (70). - System (2) according to one of claims 6 to 9,
characterised in that the internal IT level (60) is connected via a local network, in particular ethernet (50), to the data transmission device (26). - System (2) according to one of the preceding claims,characterised in that the sensor device (24) has at least one of the following sensors:- temperature sensor (72),- pressure sensor (74),- throughflow sensor/flow sensor (76),- end position sensor (78),- conductivity sensor (80),- turbidity sensor/suspended particle sensor (82),- viscosity sensor (84),- pH value sensor (86),- foam sensor (88),- level sensor (90),- empty warning sensor (92),- image sensor (94), in particular video camera,- position monitoring sensor (96),- wear sensor (98),- UV light sensor (100),- flushing device monitoring sensor (102) for detecting a non-explosive atmosphere,- water sensor (104),- torque sensor (106),- weight sensor (108),- rotation speed sensor (110),preferably the end position sensor (78) sensing the end position of at least one of the following:- valve setting,- manhole setting,- cover position,- bend coupling installation,and/or the position monitoring sensor (96) being configured as vibration sensor.
- System (2) according to at least one of the preceding claims,characterised in that the container (6) has one, several or all of the following sensors:- temperature sensor (72),- pressure sensor (74),- end position sensor (78),- foam sensor (88),- level sensor (90),- empty warning sensor (92),- image sensor (94),- weight sensor (108),and/or the agitator (8) has one, several or all of the following sensors:- position monitoring sensor (96),- wear sensor (98),- flushing device monitoring sensor (102) for detecting a non-explosive atmosphere,- rotation speed sensor (110),- torque sensor (106),and/or the homogeniser (38) has one, several or all of the following sensors:- pressure sensor (74),- position monitoring sensor (96),- wear sensor (98),- flushing device monitoring sensor (102) for detecting a non-explosive atmosphere,- rotation speed sensor (110),- torque sensor (106).
- System (2) according to one of the preceding claims,
characterised in that the sensor device (24) has at least one analogue-digital converter (112) for converting an analogue sensor signal into a digital sensor signal. - System (2) according to one of the preceding claims,
characterised in that the remote control device (30) is fitted to implement at least one of the following:- evaluating sensor data and detecting process information, in particular in real time,- archiving sensor data and/or process information. - System (2) according to one of the preceding claims,
characterised in that the wear component is at least one of the following:- mechanical seals of the homogeniser,- homogeniser mixing element (37),- valve seals,- pumps,- mechanical seals of the agitator,- scraper of the agitator,- heat exchanger.
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DE202019006042U1 (en) | 2024-04-19 |
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