Smart connection system and method

Abstract

A bulk transfer system that reduces piping complexity and that eliminates the possibility of connection errors occurring during the transfer of materials to a downstream destination. The bulk transfer system uses a Programmable Logic Controller (PLC) to verify that the correct output line is used. Further, the PLC sequences material draws such that it is possible to use fewer pumps to move the same amount of material to its destination.

Description

FIELD OF THE INVENTION[0001]This invention relates generally to devices, systems and methods used in the bulk products industry and has specific application in the plastic extrusion industry for the fabrication of extruded plastic products. More specifically, the claimed invention relates to a system and method for sequencing draws on a given plastic resin line used in an extrusion production set-up, thus preventing two vacuum pumps from pulling on the same line at the same time and eliminating the need for multiple resin lines for each ingredient. It also relates specifically to such a system and method where cross-checking of material connections can be made for desired resin blending, or “recipes.”BACKGROUND OF THE INVENTION[0002]In the plastic extrusion industry, raw plastic material, called “resin” in the industry, is melted and formed into a continuous profile. Extrusion produces items such as piping, tubing, window frames, and the like. In the extrusion of plastics, raw therm...

AI Technical Summary

Benefits of technology

The claimed invention is a new system and method that solves two problems faced by the plastics industry: piping complexity and connection errors during the extrusion process. The system uses a programmable automation controller to recognize which ingredient is connected to which material line, preventing multiple pumps from pulling on the same line at the same time. It also allows for a cross-check of the material connections versus the desired recipe, ensuring accuracy. The invention has applications beyond the plastics industry.

Problems solved by technology

Additionally, most extrusion processing factories are doing shorter runs which results in more product changeovers.

This industry trend presents some problems for plastic extrusion converting factories.

The first problem relates to piping complexity.

Historically, there was no way of knowing which line was connected where and this presented a problem.

This presents a piping challenge in both real estate and cost.

The second problem relates to connection errors.

With the very sophisticated piping arrangements required for the applications mentioned above, there are literally thousands of combinations of connections that can be made, thus leaving room for human error.

Errors can cost extrusion processors tens of thousands of dollars in waste and lost production time.

The costs increase exponentially if a “bad” product, i.e. a product fabricated with incorrect ingredients, makes it to the end user or to another step of the converting process.

Other industries share similar problems related to complex piping arrangements and potential connection errors.

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