ES2943757B2 - PROCEDURE AND DEVICE FOR COUNTING AND CONTROLLING FILM FOR A BALING MACHINE - Google Patents

Description

DESCRIPTION

PROCEDURE AND DEVICE FOR COUNTING AND CONTROLLING FILM FOR A BALING MACHINE

The invention relates to a procedure and a device adaptable to a large majority of wrapping machines (rotary arm, platform, ring or any other), which measures the quantity and type of film dispensed and the number of pallets wrapped.

The device includes mechanisms for measuring the amount of film consumed and identifying the roll, obtaining data on its capacity and film type. It communicates with a server to which the data is sent. This makes it suitable for real-time monitoring of the amount of film dispensed during wrapping processes, as well as the type of film used and roll capacity, allowing for anticipation of roll change needs and film stock requirements.

The field of action of the invention is that of baling machines.

BACKGROUND OF THE INVENTION

Pallet wrapping machines are well known that perform wrapping using a reel carriage, where said reel carriages comprise a series of rollers both to support the film reel and to orient and shape the film before coming into contact with the load to be wrapped.

Patent EP1504995 refers to a baling machine that has a pair of arms that move with respect to a frame, where the ends of the arms have a film unwinding and folding device.

The applicant's own utility model U201932048 shows an autonomous baling machine suitable for both carrying out baling tasks and autonomy of movement and navigation, which has a mobile arm that moves around the load baling it.

Patent EP1714876 relates to a wrapping machine comprising a fixed frame and a platform that can rotate on said frame, an axle that supports a roll of polymeric film which can perform a translational movement around the load to be wrapped.

Patent EP 2147864 of the applicant refers to a fixed machine which has a rotating arm that orbits around the load to be wrapped. This arm has a reel carriage with rollers at one end, where at least one of them houses a film reel and the others help to tension the film before starting the wrapping process.

US patent 2022355962 relates to a system comprising a wrapping machine, a plurality of sensors configured to detect the machine's operation, and a controller connected to the sensors. The controller is configured to set desired values for the machine's operating parameters, monitor the actual values of the operating parameters using sensor data during machine operation, and, in response to a difference between the desired and actual values that exceeds a threshold, issue a command to adjust the machine's operation so that the difference is less than the threshold.

None of the above inventions contemplates a device independent of the wrapping machine where its objective is the control of stock based on the amount of film consumed and that has elements that can be used to perform said control allowing real-time monitoring of film consumption automating inventory control and being able to automate stock replenishment times without the need to request it manually.

DESCRIPTION OF THE INVENTION

The invention relates to a method and a device that allows for determining the number of wrapping cycles, the amount of film dispensed, the film type, and other characteristics of the roll, such as its type and total and remaining capacity. With the data obtained, through processing and combination, it is possible to determine wrapping efficiency, plan the stock of rolls of each type, and anticipate roll replacement needs.

This device operates independently of the machine it is attached to, making it suitable for use with wrapping machines. The device collects data and sends it to a server.

Its operation is parallel to that of the machine to which it is attached, so that there is no interference between the data obtained by the device and that obtained by the machine, avoiding duplications or errors that can distort the final information, making it ideal to be a device that can be installed on a pre-existing baling machine.

The mention that its operation is in parallel to the machine to which it is added should be understood as meaning that it does not share resources with it beyond, in any case, the power supply and support, being able to be added to a pre-existing machine and the operation of the device being independent, although obviously coordinated, from that of the machine.

The control device operates in real time, sending the collected information to the server.

The real-time procedure allows you to determine both the number of meters of film consumed and the number of pallets wrapped, and therefore the number of meters required for each pallet, allowing you to make stock forecasts and forecasts of coil change requirements for each type.

The device comprises:

- A communications and management module suitable for communicating with at least one server.

- A first element for identifying the film reels. This first element comprises:

- Means of identifying the film reel.

- Means to communicate with other elements, modules or servers.

- A second element that counts the meters of film during the wrapping cycles. This second element comprises:

- Means of measuring the dispensed film.

- Means to communicate with other elements, modules or servers.

- A power supply, preferably a 220VAC and 24VD input, that powers the device.

- Optionally, connection means (input/output) for other peripherals.

The first element comprises means for identifying the film reel, preferably an RFID reader/peripheral, which detects and reads tags placed on the film reels, preferably on the core. This reader is in constant communication with the communications and management module, and the latter with the server.

The second element, suitable for measuring the length of film dispensed, comprises measuring devices such as, among others, a tachometer or a sensor. This measuring device can also measure the number of wrapping cycles and, therefore, the number of pallets wrapped.

This second element is preferably placed at any point along the film's path, from the reel to the pallet, with its location being suitable on the last roller of the reel carriage through which the pre-stretched film passes.

In a preferred execution, the first and second elements communicate directly with the communications and management module, although in a possible execution, the first and second elements have means to communicate directly with a server.

The procedure comprises the following phases:

- A first activation phase in which the device is activated prior to the start of the baling process.

- A second recognition phase in which the first element identifies the film reel positioned on the reel carrier using the peripheral reader and the identification card, which in a preferred embodiment will be an RFID reader and an RFID tag. The recognition comprises:

oA first sub-phase where the peripheral reader detects the identification label placed on the reel, which contains information about the characteristics of the film reel.

A second sub-phase where the first element sends the collected information to the server, preferably through the communications and management module.

A third sub-phase in which the server relates this information to the information it stores about that same coil to determine:

■ The type of film and reel.

■ The footage available, for which it will be determined if it has been used previously and if so, how many meters of film remain.

■ The stock of this type of coil to determine, according to predetermined data, whether it is necessary to restock.

■ Whether the film is suitable for the wrapping operation.

- A third calibration phase (to be performed only once) of the second element in relation to the point where the reading is taken, which must determine the measurement pattern that will serve as a parameter to perform the counting of meters of film in the wrapping process.

- A fourth phase of starting the counting of meters of film, in which once the second element has been calibrated and the film has been placed by the rollers of the reel carriage, the wrapping begins and the counting of meters begins in parallel.

- A fifth completion phase in which the baling and meter counting are stopped, where the collected information is sent to the server, preferably through the communications and management module.

- A sixth phase of information transformation and data cross-referencing. In this phase, information is transformed into measurable data and cross-referenced with pre-existing data on the server in order to determine one or more of the following data:

- Quantity of film in stock of the required type.

- Film consumption per pallet.

- Number of pallets for which there is still film stock.

- Wrapping efficiency compared to previous wrapping processes. - A seventh warning phase in case parameters outside the predetermined acceptable parameters are detected, for example, minimum stock quantity or amount of film per pallet.

Before the wrapping machine begins the wrapping process, the device is activated, and the first element recognizes the reel, including the available footage, film type, and reel type. This is possible because the first element includes a reader, such as the previously mentioned RFID reader, which is suitable for reading the identification tag (e.g., RFID) containing the reel information. In a preferred embodiment, the tag is mounted on the reel itself, for example, inside the core, and the reader is mounted on the shaft that supports it. In this way, the reel mounted on this shaft is identified and characterized by the reader.

In a preferred execution, the information collected includes data on whether the reel is new or has been previously used, calculating the amount of film remaining in the latter case and, in both cases, the film type. The communication and management module stores the information in its data persistence and sends it to the server, which processes it, keeping the data updated.

As mentioned, in a preferred execution, the label or “tag” is placed on the mandrel of the reel, and the reader on the shaft that supports it during use, generating a constant reading of the label which allows the data to be kept up to date.

In a preferred embodiment, the second element is arranged on the film output roller, through which the film passes already pre-stretched by the action of a pre-stretch motor, which facilitates the measurement and the relationship between the meters of film dispensed and the requirements for wrapping a pallet.

In one possible embodiment, the second element comprises an inductive sensor arranged on the film output roller.

In another possible implementation, the pallet count is performed by activating the wrapping machine in such a way that each time the machine is turned on, it is determined that a pallet has been wrapped, generating a progressive count of the number of pallets already wrapped.

The inductive sensor counts the meters of film according to the initial calibration described earlier. For this initial calibration, the diameter of the last roller where the film is stretched must be known. The inductive sensor is positioned at a distance that allows it to detect this last roller (for example, the roller is detected twice per revolution). The roller diameter is divided by the number of times the sensor detects the roller per revolution, and the resulting data is sent to the server, which processes it as a parameter to help determine the amount of film consumed per roll and/or per pallet.

In a preferred execution, to check the correct operation of the device, its start-up and stop in relation to the last roller of the reel carriage, detecting possible faults, the power board of the film pre-stretch motor is connected to the input of the device. This motor has power outputs that send information to the device about when the pre-stretch motor starts, thus enabling the correct activation of the device.

If the pre-stretch motor starts and the device does not activate, the information is sent to the server which recognizes this data as a fault, generating an alert in the system about the failure.

In another possible implementation, communication between the device and the pre-stretch motor is via wireless technology or other means that allow it.

By reading the identification labels on the film reels and the data obtained by the sensors for controlling film footage, a relationship is established between the real-time consumption of film (preferably measured in meters) and the film reels in the current stock, which allows the level of film footage consumption to be established in a given period in order to place orders for film reels in an automated way.

In a possible execution, alerts (visual, acoustic, or of any other type) can be generated that indicate, for example, the need to change the reel or that the stock level is below a previously established threshold so that either an automatic order for film reels is generated or it is only as a communication for the user to place the order.

The device can be installed on any baling machine, or on any type of machine that requires these features (labelers, scales, etc.) which facilitates its implementation both on new machines and on machines that are already in use, making its installation quick and easy.

In a possible implementation, the device is powered by batteries.

BRIEF DESCRIPTION OF THE FIGURES

FIGURE 1 shows a wrapping machine (1) of the rotating arm type that mounts a reel carriage (2) where the reel shaft (3) is located, where the reader - for example RFID - is housed, and the last output roller (4) where the film measuring element is located, such as a tachometer or a sensor.

FIGURE 2 shows a film reel (5) with the identification card (6) arranged on the inner tube or mandrel.

DESCRIPTION OF A WAY OF CARRYING OUT THE INVENTION

This section presents a possible implementation of the invention, which is not limiting but merely expository: a device and a procedure for counting and controlling the film to be dispensed by a baler.

The device comprises at least the following elements:

A first element comprising an RFID tag reader, this reader being arranged on the axis of the film reel (3). This reader is suitable for reading identification cards (Tags) (6) arranged on the reel core (5) and containing reel identification data, specifically film length and type.

This data is sent to a communications and management module.

A second element is located in the film path, specifically on the exit roller (4) of the reel carriage. This element, which includes a tachometer, is suitable for measuring the amount of film dispensed.

The data with the measurement of the dispensed film are sent to the communications and management module.

A communications and management module suitable for receiving data from the first and second elements and sending them to a server where they are transformed and processed, also using pre-existing data on the server.

The procedure for measuring and controlling the film in a baler comprises the following phases and sub-phases:

- A first activation phase in which the device is activated prior to the start of the baling process.

- A second recognition phase in which the first element identifies the film reel positioned on the reel carrier using the RFID tag. The recognition process includes:

oA first sub-phase where the RFID reader detects the RFID tag placed on the reel which contains information about the characteristics of the film reel.

A second sub-phase where the first element sends the collected information to the server, preferably through the communications and management module.

A third sub-phase in which the server relates this information to the information it stores about that same coil to determine:

■ The type of film and reel.

■ The footage available, for which it will be determined if it has been used previously and if so, how many meters of film remain.

■ The stock of this type of coil to determine, according to predetermined data, whether it is necessary to restock.

■ Whether the film is suitable for the wrapping operation.

- A third calibration phase (to be performed only once) of the second element in relation to the point where the reading is taken, which must determine the measurement pattern that will serve as a parameter to perform the counting of meters of film in the wrapping process.

- A fourth phase of starting the counting of meters of film, in which once the second element has been calibrated and the film has been placed by the rollers of the reel carriage, the wrapping begins and the counting of meters begins in parallel.

- A fifth completion phase in which the baling and meter counting are stopped, where the collected information is sent to the device which sends it to the server for processing.

- A sixth phase of information transformation and data cross-referencing. In this phase, information is transformed into measurable data and cross-referenced with pre-existing data on the server in order to determine one or more of the following data:

- Quantity of film in stock of the required type.

- Film consumption per pallet.

- Number of pallets for which there is still film stock.

- Wrapping efficiency compared to previous wrapping processes. - A seventh alert phase in case parameters outside the predetermined data are detected, for example, minimum stock quantity or amount of film per pallet.

Claims (7)

1. FILM COUNTING AND CONTROL DEVICE FOR A BALING MACHINE that operates in collaboration with a server with which it communicates and to which it sends data, characterized in that the device: a. Collect data relating to the characteristics of the film roll and the film consumption per pallet. b. Sends this data in real time to a server that is suitable for managing the stock of film reels. For which the device comprises; - A communications and management module suitable for communicating with at least one server. - A first element for identifying the film reels. This first element comprises: - Means of identifying the film reel. - Means of communicating with other elements. - A second element for measuring the quantity of film during the wrapping cycles. This second element comprises: - Means of measuring the dispensed film. - Means of communicating with other elements. - A power supply The device being suitable for installation on a pre-existing wrapping machine where the first element for identifying the film reels works in conjunction with an identification card arranged on the film reels (5) and the second element for measuring the quantity of film is arranged in the film path between the reel and the pallet to be wrapped, and in which the means for measuring the quantity of film dispensed by the second element comprise an inductive sensor for counting meters of film and pallets, which is arranged in the film path after its pre-stretching and on the last film output roller. 2. - FILM COUNTING AND CONTROL DEVICE FOR BALING MACHINE according to claim 1 characterized in that it further comprises connection means (input/output) for other peripherals. 3. - FILM COUNTING AND CONTROL DEVICE FOR A BALING MACHINE according to claim 1 characterized in that the first element for identifying the film reels comprises an RFID reader and an RFID identification card (6), the identification card being disposed on the reel (5) 4. - FILM COUNTING AND CONTROL DEVICE FOR BALING MACHINE according to claim 3 characterized in that the RFID cards are arranged in the mandrel of the dispensing reel. 5. - FILM COUNTING AND CONTROL DEVICE FOR BALING MACHINE according to claim 1 characterized in that the measuring element of the second film quantity measuring element comprises a tachometer. 6. - PROCEDURE FOR CONTROLLING BALING IN A BALING MACHINE that uses a device like that of any of the preceding claims, characterized in that it comprises the following phases: - A first activation phase in which the device is activated prior to the start of the baling process. - A second recognition phase in which the first element identifies the film reel positioned on the reel carrier using the identification label. The recognition process includes: oA first sub-phase where the reader detects the identification label placed on the reel which contains information about the characteristics of the film reel. A second sub-phase where the first element sends the collected information to the server either directly or through the communications and management module. A third sub-phase in which the server relates this information to the information it stores about that same coil to determine: ■ The type of film and reel. ■ The available film length, which will determine if it has been used previously and, if so, how many meters of film remain. ■ The stock of this type of reel, in order to determine, based on predetermined data, whether it is necessary to restock. ■ Whether the film is suitable for the wrapping operation. - A third calibration phase (to be performed only once) of the second element measuring the quantity of film in relation to the point where the reading is taken, which must determine the measurement pattern that will serve as a parameter to perform the counting of meters of film in the wrapping process. - A fourth phase, once the wrapping cycle has begun, involves measuring the dispensed film. - A fifth phase, at the end of the wrapping cycle, in which the information collected during the cycle is sent to the server for processing, either directly or through the communications and management module. - A sixth phase of information transformation and data cross-referencing. In this phase, the information is transformed into measurable data and cross-referenced with pre-existing data on the server, including that collected by the first element, in order to determine one or more of the following data: - Quantity of film in stock of the required type. - Film consumption per pallet. - Number of pallets for which there is still film stock. - Efficiency of baling compared to previous baling. 7.- PROCEDURE FOR THE CONTROL OF BALING IN A BALING MACHINE according to claim 11 characterized in that it comprises a seventh warning phase in case parameters outside of predetermined data are detected.