Method and apparatus for controlling thermal changes during glass tube conversion

Abstract

A method of producing articles from glass tubing includes securing a working end of a glass tube in a glass tube holder of a converter, the converter having a plurality of processing stations, including a heating station and a forming station. The glass tube of initial length includes a plurality of successive sections, each of the plurality of successive sections corresponding to one article and having an article number. The method includes heating the working end of the glass tube in the heating station, adjusting an amount of heating of the glass tube in the heating station based on the article number at the working end of the glass tube; and forming a feature of the article in the forming station. Adjusting the amount of heating based on the article number reduces variation in tube temperature and / or article dimensions between one article number and a next article number.

Description

[0001] Cross-reference to related applications

[0002] This application is based on the priority interest in U.S. Provisional Application No. 63 / 066,475, filed on August 17, 2020, the contents of which are incorporated herein by reference in their entirety. background Technical Field

[0004] This specification generally relates to systems and methods for producing glass articles from glass tubes, and in particular to systems and methods for reducing temperature and dimensional changes during glass tube conversion processes. Background Technology

[0006] Historically, glass has been a preferred material for packaging pharmaceuticals due to its airtightness, optical clarity, and excellent chemical durability compared to other materials. Specifically, glass used for pharmaceutical packaging must possess sufficient chemical durability to prevent affecting the stability of the pharmaceutical formulation contained therein. Glasses with suitable chemical durability are those included in the “Type IA” and “Type IB” glass compositions of the ASTM standards, which have a proven history of chemical durability.

[0007] Glass tubes can be converted into other glass products, such as various glass containers for pharmaceutical applications, including but not limited to vials, syringes, ampoules, cartridges, and other glass products. Glass tubes can be converted, for example, in a "converter." Converters have been used for over 75 years and are currently manufactured by various commercial and in-house instrument suppliers. These converters typically use steps including flame processing, rotary and static tooling, thermal separation, or scribing and impact cutting to reshape long glass tubes into multiple glass products. A series of burners is often used to separate a portion or section from the glass tube and shape it to a specific size. Summary of the Invention

[0008] During the conversion process, the temperature of a glass tube of a certain length loaded in the converter can vary as the glass tube is consumed multiple times through the conversion process. These temperature variations of the glass tube of this length can cause changes in the size and appearance of the glass articles made from the glass tube. Therefore, there is a need for systems and methods for converting glass tubes into glass articles (e.g., pharmaceutical packaging) while reducing the temperature variations of the glass tube during the incremental consumption of the glass tube in the conversion process.

[0009] In a first aspect of this disclosure, a method for producing multiple articles from a glass tube may include: securing a working end of the glass tube in a glass tube holder of a converter having multiple processing stations, including at least one heating station and at least one forming station following the at least one heating station. The converter may move the glass tube holder through the multiple processing stations. The glass tube of initial length may include multiple consecutive segments, each of the multiple consecutive segments corresponding to an article and having an article number. The method may further include heating the working end of the glass tube at the at least one heating station and increasing or decreasing the amount of heating on the glass tube based on the article number corresponding to the working end of the glass tube. Increasing or decreasing the amount of heating based on the article number may reduce the variation in tube temperature and / or article size between one article number and the next article number. The method may further include: forming at least one feature of the article at the working end of the glass tube at the at least one forming station; separating the article from the working end of the glass tube at a separation station; and rotating the glass tube downward in the glass tube holder to form a subsequent article.

[0010] The second aspect of this disclosure may include the first aspect, wherein increasing or decreasing the heating amount of the glass tube may include at least one of the following: increasing or decreasing the burner residence time of the working end of the glass tube in contact with the heating element in the at least one heating station based on the product number at the working end of the glass tube; increasing or decreasing the heating rate of the heating element in the at least one heating station based on the product number at the working end of the glass tube; or adjusting the negative pressure generated by the exhaust system near the glass tube in the at least one heating station based on the product number at the working end of the glass tube.

[0011] The third aspect of this disclosure may include either the first or the second aspect, wherein the plurality of processing stations may include a plurality of heating stations, and the method may include: increasing or decreasing the heating amount of the glass tube in each of the plurality of heating stations based on the article number corresponding to the working end of the glass tube.

[0012] The fourth aspect of this disclosure may include any one of the first to third aspects, wherein the variation of tube temperature and / or article size at the working end of the glass tube may vary according to the article number of the article formed at the working end of the glass tube.

[0013] The fifth aspect of this disclosure may include any one of the first to fourth aspects, wherein increasing or decreasing the heating amount at the working end of the glass tube may include: increasing or decreasing the burner residence time of the glass tube in contact with the heating element in the at least one heating station based on the article number at the working end of the glass tube.

[0014] The sixth aspect of this disclosure may include the fifth aspect, wherein the heating element in the at least one heating station may include a rotary burner that may pivot to engage or not engage with the working end of the glass tube.

[0015] The seventh aspect of this disclosure may include the sixth aspect, wherein increasing or decreasing the burner dwell time may include: adjusting the time during which the rotary burner pivots to engage or not engage with the working end of the glass tube.

[0016] The eighth aspect of this disclosure may include any one of the first to seventh aspects, wherein increasing or decreasing the heating amount at the working end of the glass tube may include: increasing or decreasing the heating rate of the heating element in the at least one heating station based on the article number at the working end of the glass tube.

[0017] The ninth aspect of this disclosure may include the eighth aspect, wherein the heating element may include a burner, and increasing or decreasing the heating rate may include increasing or decreasing the flow rate of one or more combustion gases supplied to the burner. The combustion gases may include fuel gas as well as oxygen and / or air.

[0018] The tenth aspect of this disclosure may include the ninth aspect, wherein increasing or decreasing the heating rate may include: proportionally increasing or decreasing the flow rate of all combustion gases reaching the burner.

[0019] The 11th aspect of this disclosure may include the 9th aspect, wherein increasing or decreasing the heating rate may include: changing the flow ratio of fuel gas to oxygen supplied to the burner.

[0020] The 12th aspect of this disclosure may include any one of the 1 to 11 aspects, wherein increasing or decreasing the heating amount at the working end of the glass tube may include: adjusting the negative pressure generated by the discharge system near the at least one heating station based on the article number at the working end of the glass tube.

[0021] The 13th aspect of this disclosure may include the 12th aspect, wherein adjusting the negative pressure generated by the exhaust system near the at least one heating station may include: increasing or decreasing the speed of an air processor fluidly connected to an inlet vent located near the at least one heating station; and / or adjusting the position of a damper disposed between the air processor and the inlet vent.

[0022] The 14th aspect of this disclosure may include the 12th aspect, wherein adjusting the negative pressure generated by the exhaust system near the at least one heating station may include: adjusting the position of the inlet vent of the exhaust system relative to the glass tube in the at least one heating station.

[0023] The 15th aspect of this disclosure may include any one of the 1 to 14 aspects, wherein the converter may include a plurality of glass tube holders, and the method may include: moving each of the plurality of glass tube holders through each of a plurality of processing stations, and increasing or decreasing the amount of heating at the working end of the glass tube based on the article number each time the plurality of glass tube holders move to the next processing station.

[0024] The 16th aspect of this disclosure may include any one of aspects 1 to 14, and further includes: after the production of the final article corresponding to the final article number of the glass tube, fixing the glass tube of the new length in the tube holder.

[0025] The 17th aspect of this disclosure may include the 16th aspect, wherein the converter may include a plurality of glass tube holders, and the method may further include: securing glass tubes of new lengths in each of the plurality of tube holders in a sequential order, starting from a first glass tube.

[0026] The 18th aspect of this disclosure may include the 17th aspect, which includes: in response to a change in the article number at the working end of the first glass tube at the at least one heating station, changing the heating amount at the working end of the first glass tube based on the article number, and maintaining the heating amount at the at least one heating station between glass tubes until the first glass tube returns to the at least one heating station and the article number at the working end of the first glass tube changes.

[0027] In a 19th aspect of this disclosure, a method for producing multiple articles from a glass tube may include: introducing the glass tube into a glass tube holder of a converter having multiple processing stations, including at least one heating station and at least one forming station following the at least one heating station. The converter may move the glass tube holder through the multiple processing stations. The method may further include: heating a working end of the glass tube at the at least one heating station; and at the at least one forming station, forming at least one feature of a first article at the working end of the glass tube, the first article corresponding to a first consecutive position along the length of the glass tube. The method may further include: separating the first article from the working end of the glass tube at a separation station, and after separation, rotating the glass tube downward in the glass tube holder to form a second article from the glass tube, the second article corresponding to a second consecutive position along the length of the glass tube. The method may further include: heating the working end of the glass tube corresponding to the second consecutive position at the at least one heating station; and increasing or decreasing the amount of heating of the glass tube corresponding to the second consecutive position relative to the heating of the first article. Increasing or decreasing the heating amount at the working end of the glass tube relative to the first product can reduce the temperature or dimensional changes of the second product relative to the first product.

[0028] In a 20th aspect of this disclosure, a system for producing multiple articles from a glass tube may include: a converter comprising multiple processing stations, including at least one heating station, at least one forming station, and a separating station. The converter may be used to move the glass tube through the multiple processing stations. The system may further include a system controller communicatively connected to the converter. The system controller may include a processor and a storage medium containing computer-readable and executable instructions, which, when executed by the processor, may cause the system controller to automatically determine an article number at a working end of the glass tube, wherein the article number comprises an integer corresponding to a consecutive segment of the glass tube of an initial length, each consecutive segment corresponding to one article; and, based on the article number at the working end of the glass tube, increase or decrease the heating amount of the glass tube at the at least one heating station.

[0029] The 21st aspect of this disclosure may include the 20th aspect, wherein the at least one heating station may include a rotary burner operable to pivot into or out of engagement with the working end of the glass tube, and a system controller may be communicatively connected to the rotary burner.

[0030] The 22nd aspect of this disclosure may include either the 20th or 21st aspect, wherein, when the processor executes computer-readable and executable instructions, the instructions may cause the system controller to automatically increase or decrease the burner dwell time at the working end of the glass tube by pivoting the rotary burner to engage or disengage with the working end of the glass tube based on the article number at the working end of the glass tube.

[0031] The 23 aspects of this disclosure may include any one of aspects 20 to 22, wherein the at least one heating station may include at least one burner and at least one flow controller, which can be used to increase or decrease the mass flow rate of one or more combustion gases reaching the at least one burner.

[0032] The 24th aspect of this disclosure may include the 23rd aspect, wherein, when the processor executes computer-readable and executable instructions, the instructions may cause the system controller to automatically increase or decrease the mass flow rate of one or more combustion gases reaching the at least one burner based on the article number at the working end of the glass tube.

[0033] The 25th aspect of this disclosure may include any one of aspects 20 to 24, wherein the converter may include an exhaust system comprising at least one inlet vent and an air processor fluidly connected to said at least one inlet vent.

[0034] The 26th aspect of this disclosure may include the 25th aspect, wherein when the processor executes computer-readable and executable instructions, the instructions may cause the system controller to automatically adjust the negative pressure generated by the discharge system near the glass tube based on the article number at the working end of the glass tube.

[0035] It should be understood that the foregoing general description and the following detailed description both depict various embodiments and are intended to provide an overall assessment or framework for understanding the nature and characteristics of the claimed subject matter. The included drawings provide a further understanding of the various embodiments and are incorporated in and form a part of this specification. The drawings illustrate the various embodiments described herein and, together with the description, serve to explain the principles and operation of the claimed subject matter. Attached Figure Description

[0036] Figure 1 According to one or more embodiments shown and described herein, an embodiment of a converter for producing glass articles from glass tubes is schematically depicted.

[0037] Figure 2 Based on one or more embodiments shown and described herein, a schematic depiction is provided. Figure 1 A top view of the main rotary table, secondary rotary table, and feed rotary table of the converter;

[0038] Figure 3A Based on one or more embodiments shown and described herein, a schematic depiction is provided. Figure 1 The heating station of the converter;

[0039] Figure 3B Based on one or more embodiments shown and described herein, a schematic depiction is provided. Figure 1 The forming station of the converter;

[0040] Figure 3C Based on one or more embodiments shown and described herein, a schematic depiction is provided. Figure 1 Another implementation of the forming station of the converter;

[0041] Figure 3D Based on one or more embodiments shown and described herein, a schematic depiction is provided. Figure 1 Cooling station for the converter;

[0042] Figure 3E Based on one or more embodiments shown and described herein, a schematic depiction is provided. Figure 1 The converter's separation station;

[0043] Figure 3F Based on one or more embodiments shown and described herein, a schematic depiction is provided. Figure 1The through-station of the converter;

[0044] Figure 4 Based on one or more embodiments shown and described herein, an illustration is provided in... Figure 1 A perspective view of the glass tube before conversion in the converter;

[0045] Figure 5 The illustration shows how the characteristic dimensions (y-axis) of the glass vial vary according to the product number (x) produced, without compensation for thermal changes in the glass tube.

[0046] Figure 6 Based on one or more embodiments shown and described herein, a schematic depiction is provided. Figure 1 Another heating station for the converter;

[0047] Figure 7A Based on one or more embodiments shown and described herein, a schematic depiction is provided. Figure 1 A top view of the rotary burner of the converter, the rotary burner in Figure 6 In the heating station, it is positioned where it connects with the glass tube;

[0048] Figure 7B Based on one or more embodiments shown and described herein, a schematic depiction is provided. Figure 1 A top view of the rotary burner of the converter, the rotary burner in Figure 6 In the heating station, it is positioned in a position not connected to the glass tube;

[0049] Figure 8 According to one or more embodiments shown and described herein, the burner is illustrated with and without alteration. Figure 6 The dimensions (y-axis) of the glass product vary according to the product number (x) depending on the dwell time in the heating station;

[0050] Figure 9 According to one or more embodiments shown and described herein, the temperature (y-axis) of the glass tube varies with time (x) during the residence time of the burner in the heating station in FIG7.

[0051] Figure 10A The illustration shows how the dimensions (y-axis) of the product vary according to the product number (x) without compensation for the thermal changes of the glass tube during the transition.

[0052] Figure 10B According to one or more embodiments shown and described herein, the adjustment of the burner in Figure 6The dimensions (y-axis) of the product vary according to the product number (x) under the condition of the heating rate in the heating station;

[0053] Figure 11 Based on one or more embodiments shown and described herein, a schematic depiction is provided. Figure 1 Another heating station for the converter; and

[0054] Figure 12 According to one or more embodiments shown and described herein, the dimensions (y-axis) of the article vary with the number of parts (x) at various exhaust flow rates. Detailed Implementation

[0055] The following detailed description refers to embodiments of systems and methods for reducing temperature and dimensional variations in glass articles produced by conversion processes for transforming glass tubes into glass articles, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numerals will be used throughout the drawings to refer to the same or similar parts. Glass tubes can be converted into glass articles, particularly glass containers for pharmaceutical applications, including but not limited to vials, syringes, ampoules, cartridges, and other glass articles. Converters can be used to convert glass tubes into these glass articles; for example, converters comprising multiple processing stations. Among other types of processing stations, processing stations may particularly include heating stations, forming stations, thermal separation stations, and through-processing stations. Converters typically employ steps to reshape a long glass tube length into multiple glass articles, including but not limited to flame processing, rotary and stationary tooling, thermal separation, or scribing and impact cutting steps. Thus, glass articles produced by conversion processes performed on a converter undergo a series of flame burners and other heating elements to separate a portion from the glass tube and shape that portion into a specific size.

[0056] During the conversion process, the glass tube is loaded into the converter at room temperature (approximately 23°C). However, during the consumption of the glass tube, the temperature of the non-working portion of the glass tube can rise to over 200°C due to heat emitted by the flame burner on the converter or conversion machine. As the glass tube nears complete consumption, its shortest length can result in a higher airflow rate through the tube, which also affects the glass tube temperature. Temperature variations in the glass tube during processing and consumption can cause dimensional and appearance changes in the glass products formed during the conversion process. These temperature variations, and the resulting dimensional and appearance changes, can limit the operating window of the conversion process, reduce process capacity (Cpk), and decrease yield. This reduction in yield may result from a lower production rate or yield loss, which is caused by non-conforming products due to dimensional and appearance changes. For SKU numbers operating under certain process conditions, yield losses due to dimensional and appearance changes can exceed 30%, and at least a portion of this yield loss can be attributed to temperature variations in the glass tube during the conversion.

[0057] Various solutions have been proposed to reduce temperature changes in glass tube preforms during consumption, but none have been found sufficient to significantly reduce dimensional and appearance changes caused by these temperature variations. For example, some operators preheat the glass tubes on the conveyor belt or above the machine before loading them into the converter. This method is not feasible in existing conversion processes because the tube loader is made of plastic to avoid metal-glass contact, and preheating the glass tube to a sufficient temperature to reduce thermal changes that could deform the plastic of the tube loader. In another proposed solution, the glass tube is either sealed or sealed and vented to prevent heated gases from flowing upward through the central chamber of the glass tube. However, sealed or sealed and vented glass tubes require specialized forming equipment on the converter, and even during implementation, thermal changes in the process cannot be eliminated.

[0058] Therefore, there is a growing need for systems and methods for converting glass tubes into glass articles (e.g., pharmaceutical packaging) while minimizing temperature variations in the glass tubes during incremental consumption in the conversion process. The systems and methods disclosed herein relate to adjusting the heating of the glass tube based on the article number at the working end of the glass tube to compensate for temperature variations along a length of the glass tube as it is consumed. The heating of the glass tube as it is consumed can be performed on a per-article basis and / or based on each revolution of the main turntable.

[0059] The initial length of the glass tube can be conceptually divided into multiple consecutive segments, each corresponding to a product and associated with a product number. As the first product made from the glass tube is designated as product number 1, the temperature of each subsequent consecutive segment varies with increasing product number. Using a relational database tracking product numbers at the working end of the glass tube, the burner residence time, burner output / heating rate, or exhaust flow based on each product can be controlled by a controller to adjust the tube temperature towards a more "steady-state" condition.

[0060] Figure 1 One embodiment of a system for producing articles from glass tubes is shown. Figure 1 In the illustrated embodiment, the system for producing glass articles from a glass tube 102 includes a converter 100 having multiple processing stations 106, including at least one heating station, at least one forming station, and a separating station. The converter 100 is used to move the glass tube 102 through the multiple processing stations 106. (Reference) Figure 5 The system may include a system controller 400 that is communicatively connected to the converter 100. Figure 5 The system controller 400 is operable to determine the product number at the working end 150 of the glass tube 102 and to increase or decrease the heating amount of the glass tube 102 in the at least one heating station 202 based on the product number at the working end 150 of the glass tube 102.

[0061] A method for producing multiple articles from a glass tube 102 may include: securing a working end 150 of the glass tube 102 in a glass tube holder 130 of a converter 100 having multiple processing stations 106. Each processing station 106 may include at least one heating station and at least one forming station following the at least one heating station. The converter 100 moves the glass tube holder 130 and the glass tube 102 secured therein through the multiple processing stations 106. The glass tube of initial length comprises multiple consecutive segments, each of which corresponds to an article and has an article number. The method may include: heating the working end 150 of the glass tube 102 at the at least one heating station 202; increasing or decreasing the heating amount of the glass tube based on the product number corresponding to the working end 150 of the glass tube 102; forming at least one feature of the product at the working end 150 of the glass tube 102 at the at least one forming station; separating the product from the working end 150 of the glass tube 102 at a separating station; and rotating the glass tube 102 downward in a glass tube holder 130 to form a subsequent product.

[0062] Increasing or decreasing the heating amount based on the product number can reduce the variation in tube temperature and / or product size between one product number and the next. Controlling the heating amount of the glass tube based on the product number at the working end allows for greater granularity in the control scheme and reduces process variability caused by vial numbering. This, in turn, widens the process window for the conversion process and reduces non-conforming products. Therefore, among other features, the throughput of the conversion process can be increased, particularly by reducing yield losses and increasing production rates. It should be understood that the aspects of the systems and methods disclosed herein are described in the context of conversion processes for the production of pharmaceutical vials, but it should be understood that the systems and methods are applicable to conversion processes for the production of other products, such as, but not limited to, cartridges, syringes, ampoules, etc.

[0063] The directional terms used in this article, such as up, down, right, left, front, back, top, and bottom, are only for reference to the accompanying drawings and coordinate axes, and are not intended to indicate absolute orientation.

[0064] Unless otherwise expressly stated, no method described herein should be construed as requiring its steps to be performed in a specific order, or for any device, requiring a specific orientation. Therefore, if a method claim does not actually describe the order in which its steps are to be followed, or any device does not actually describe the order or orientation of its components, or the claims or description do not otherwise specifically state that the steps are limited to a specific order, or do not describe a specific order or orientation of the device components, then in no way should the order or orientation be inferred. This applies to any possible non-expressive basis of interpretation, including: logical questions concerning the arrangement of steps, operational flow, the order of components, or the orientation of components; questions of obvious meaning derived from grammatical organization or punctuation; and questions of the number or type of embodiments described in the specification.

[0065] Unless the context clearly indicates otherwise, the singular forms “a,” “an,” and “the” used herein include plural references. Thus, for example, a mention of an “a” component includes aspects having two or more such components, unless otherwise explicitly stated in the text.

[0066] As used herein, the “working end” of the glass tube is the end of the glass tube oriented toward the processing station of the converter relative to the holder, while the “non-working end” of the glass tube is the end of the glass tube oriented away from the processing station.

[0067] As used in this article, the "dwell time" of a converter refers to the duration that the glass tube spends in a particular processing station before it is moved to the next subsequent processing station.

[0068] As used in this article, “burner residence time” refers to the duration for which the burner flame engages with the glass tube to heat it.

[0069] Now for reference Figure 1 The diagram schematically depicts a converter 100 for producing glass articles from a glass tube 102. The converter 100 can be used to convert the glass tube 102 into various glass articles, such as, but not limited to, vials, syringes, cartridges, ampoules, or other glass articles. The converter 100 includes a substrate 104 and a main turntable 108, the substrate 104 having a plurality of processing stations 106, the main turntable 108 being located above the substrate 104 and rotatable relative to the substrate 104 about a central axis A. The converter 100 may also include a glass tube loading turntable 110 located above the main turntable 108 for feeding the glass tube 102 into the main turntable 108. The converter 100 may also include a plurality of secondary processing stations 112 on the substrate 104, and a secondary turntable 114 rotatable relative to the substrate 104.

[0070] like Figure 1 As schematically shown, the base 104 of the converter 100 is stationary, and processing stations 106 can be connected to the upper portion 105 of the base 104. The plurality of processing stations 106 are spaced apart from each other and arranged in a main circuit 116. In one or more embodiments, the main circuit 116 may be annular, such that by rotating the main turntable 108 about a central axis A, the main turntable 108 can move the glass tube 102 through the plurality of processing stations 106. Alternatively, in other embodiments, the main circuit 116 may be linear. Although described herein with reference to an annular arrangement of processing stations 106, it should be understood that the subject matter disclosed herein is equally well applicable to converters having arrangements of other processing stations 106.

[0071] The type and / or shape of the articles to be manufactured from the glass tube 102 can affect the number of processing stations 106 connected to the substrate 104. The number of processing stations 106 on the main rotary table 108 can be from 14 to 32. Although the converter 100 and the conversion process are described herein in the context of a converter 100 having 16 processing stations 106 in the main line 116, it should be understood that the converter 100 may have more or fewer than 16 processing stations 106 in the main line 116. For example, but not limited to, processing stations 106 may include one or more heating, forming, polishing, cooling, separating, penetrating, measuring, feeding, or unloading stations, or other processing stations for producing glass articles from the glass tube 102. The type and / or shape of the articles to be manufactured from the glass tube 102 can also affect the type of processing stations 106 and / or the order of processing stations 106 in the converter 100.

[0072] The main turntable 108 may be located above the base 104 and may be rotatably connected to the base 104 such that the main turntable 108 can rotate relative to the base 104 about a central axis A. The main turntable 108 may be rotated relative to the base 104 using a drive motor (not shown). The main turntable 108 may include a plurality of retainers 130 configured to detachably secure each glass tube 102 to the main turntable 108. The retainers 130 may be clamps, chucks, or other retaining devices, or combinations thereof. The retainers 130 may be oriented for each glass tube 102 such that the glass tube 102 is substantially parallel to the central axis A of the main turntable 108 and substantially perpendicular to the upper portion 105 of the base 104. Although the converter 100 is described in this specification in the context of a vertically oriented converter 100, it should be understood that the converter 100 may be horizontally oriented or angularly oriented. Each retainer 130 is oriented in the direction toward the base 104 (i.e., relative to...). Figure 1 The coordinate axis (in the -Z direction) extends from the bottom 109 of the main turntable 108, and each retainer 130 is oriented such that, as it rotates about the central axis A of the main turntable 108, the glass tube 102 is positioned in or near each successive processing station 106 of the main line 116 of the base 104. The vertical orientation of the glass tube 102 allows the downwardly projecting portion of each glass tube 102 to gradually circulate through the processing stations 106 of the main line 116. In one embodiment, the converter 100 can be used to gradually transfer each of the plurality of retainers 130 through the plurality of processing stations 106. Alternatively, in one embodiment, the converter 100 can be operated to continuously balance the plurality of retainers 130 through the conversion process. Each retainer 130 can rotate independently relative to the main turntable 108 about a retainer axis D, which can be substantially parallel to the central axis A of the main turntable 108. Each retainer 130 may be operatively connected to an electric motor (not shown), a continuous drive belt, or other drive mechanism for rotating each retainer 130 relative to the main turntable 108. Rotation of the retainers 130 allows the glass tube 102 to rotate relative to a stationary burner, forming tool, cooling nozzle, or other feature of the processing station 106.

[0073] refer to Figure 1 and 2 The converter 100 may have multiple secondary processing stations 112, which are also spaced apart and arranged in secondary lines 118. Figure 2 ), and the converter 100 may have a secondary turntable 114 ( Figure 1 ), used to separate the article 103 (which has been separated from the glass tube 102) Figure 1The glass article 103 is indexed via multiple secondary processing stations 112. The secondary rotary table 114 is rotatable relative to the base 104 about a second axis B. The second axis B is generally parallel to the central axis A of the main rotary table 108. The secondary rotary table 114 also includes multiple retainers 130 to hold the glass article 103 and position it for engagement with each successive secondary processing station 112. The secondary rotary table 114 can be separated from the main rotary table 108 at the separation station 206. Figure 2 The converter receives the product 103, rotates the secondary turntable 114 to transfer the product 103 through multiple secondary processing stations 112, and unloads the finished product from the converter 100.

[0074] The glass tube loading turntable 110 can be located above the main turntable 108. In one embodiment, the glass tube loading turntable 110 can be offset from the central axis A of the main turntable 108. The glass tube loading turntable 110 can rotate about axis C, which can be substantially parallel to the central axis A of the main turntable 108. The glass tube loading turntable 110 can be independently supported in a fixed position relative to the main turntable 108, and the rotation of the glass tube loading turntable 110 can be independent of the rotation of the main turntable 108. (Reference) Figure 1 and 2 In some embodiments, the glass tube loading turntable 110 may include a plurality of loading channels 132 arranged in a ring line 134 and configured to hold the glass tube 102. The glass tube loading turntable 110 may be positioned such that one of its loading channels 132 is oriented vertically aligned (i.e., parallel to and / or aligned with the central axis A of the main turntable 108). Figure 1 In one or more embodiments, the processing station 106 of the main line 116 of the converter 100 (parallel to the Z-axis) and the corresponding retainer 130 on the main turntable 118 that passes through the processing station 106 of the main line 116. In one or more embodiments, the processing station 106 aligned with the glass tube loading turntable 110 may be the tube loading station 214. Figure 2 When the converter 100 converts all or at least a portion of the glass tube 102 at a specific retainer position 136 into one or more articles, the glass tube loading turntable 110 can transport a new length of glass tube 102 to the retainer 130 at the retainer position 136 via the top of the main turntable 108. At this time, the retainer position 136 is rotated to the tube loading station 214 of the main line 116. Figure 2Alignment. In an alternative embodiment, the converter 100 may include an arm (not shown) movable between a main turntable 108 and a glass tube loading turntable 110. When the converter 100 has converted all or part of the glass tubes 102 at a particular retainer position 136, the arm may pick up a new length of glass tube 102 from the glass tube loading turntable 110 or other glass tube gantry assembly and convey the new length of glass tube 102 to the main turntable 108 at the particular retainer position 136. Other methods and apparatus for conveying the new length of glass tube 102 to the main turntable 108 are also contemplated.

[0075] refer to Figure 2 As previously described, the multiple processing stations 106 of the converter 100 may include one or more heating stations 202, forming stations 204, separating stations 206, cooling stations 210, through-passing stations 212, pipe loading stations 214, unloading stations 216, measuring stations 218, pipe length lowering stations 220, or other stations and / or combinations of these stations. Figure 2 The arrangement of the processing stations 106 of the converter 100 is schematically depicted. The converter 100 has a main line 116 and a secondary line 118. The main line 116 has 16 processing stations 106, and the secondary line 118 has 8 secondary processing stations 112. As previously described, the processing stations 106 of the main line 116 are evenly spaced and evenly distributed around the ring line, and the secondary processing stations 112 of the secondary line 118 are also evenly spaced and evenly distributed around the ring line. Figure 2 A glass tube loading turntable 110 with multiple loading channels 132 is also schematically depicted. Figure 2 In the illustration, the glass tube loading turntable 110 is shown in a position spaced apart from the main line 116. Although the glass tube loading turntable 110 is described as having 24 loading channels 132, it should be understood that the glass tube loading turntable may have more or fewer loading channels 132 than 24.

[0076] Figure 2 The main line 116 of the converter, schematically shown, may include one or more heating stations 202, separating stations 206, through-type stations 212, one or more forming stations 204, one or more cooling stations 210, measuring stations 218, tube length lowering stations 220, and tube loading stations 214. Although Figure 2The main circuit 116 is depicted as having a ring-shaped arrangement of processing stations 106, as previously described. However, the main circuit 116 can allow the processing stations 106 to be positioned in other shapes, such as linear, polygonal, or other arrangements. For the orientation of the rotation 222 of the main turntable 108, the heating station 202 can be positioned before the separation station 206 and each forming station 204 to preheat the target area of ​​the glass tube to a target temperature at which the target area of ​​the glass tube 102 becomes sticky and deformable, and can be effectively formed or stretched and separated. At the separation station 206, the formed glass article 103 ( Figure 1 ) can be formed simultaneously at its bottom from glass tube 102 ( Figure 1 Separation. The separation station 206 can also be a processing station 106, where the partially formed glass product 103, once separated, is transferred to the secondary turntable 114. Figure 1 The glass tube 102 is rotated through a secondary line 118 having a secondary processing station 112. A through station 212 can be positioned on the main line 116, which is downstream of the separation station 206 in the direction of the rotation 222 of the main rotary table 108. At the through station 212, the meniscus 350 of the glass tube 102 previously formed in the separation station 206 is penetrated, thereby reopening the working end 150 of the glass tube 102.

[0077] Along the direction of the rotary table 222, the forming station 204 of the main line 108 can be located downstream of the through station 212. At the forming station 204, the glass tube 102 is iteratively shaped into the desired form of the finished glass article. As described above, one or more heating stations 202 can be positioned before each forming station 204 to preheat the target area of ​​the glass tube 102 to a temperature suitable for forming the glass tube 102. The forming station 204 of the main rotary table 108 is positioned opposite the working end 150 of the glass tube 102. Figure 3AThe primary stage 114 forms one end of a glass article 103, and after the glass article 103 is separated from the glass tube 102, the secondary stage 114 forms the other end of the glass article 103 at its forming station 204. In an embodiment, the converter 100 can be used to produce vials from the glass tube 102, and the forming station 204 of the converter 100 may include one or more shoulder forming stations, one or more flange forming stations, and one or more flange finishing stations, wherein one or more heating stations 202 are positioned before and between each forming station 204. The main stage 116 may also include a measuring station 218 at which a dimensional determination system (not shown) can be used to measure one or more dimensions of the glass tube 102 (e.g., diameter and thickness), and one or more dimensions of features formed by the forming stations 204. Feature dimensions may include flange thickness, flange length, neck length, neck thickness, total article length, other feature dimensions, or combinations thereof. The measuring station 218 can be located directly after the final forming station 204, so that dimensions are measured while the glass tube 102 is still at an elevated temperature. Alternatively, the measuring station 218 can be located after one or more cooling stations 210 to measure the dimensions of the glass tube 102 and / or glass articles at a lower temperature.

[0078] Still referencing Figure 2 In the direction of the indexing 222 of the main turntable 108, one or more cooling stations 210 can be positioned after the forming station 204. After the forming station 204, a tube length lowering station 220 can be positioned between the forming station 204 and the separating station 206 to lower the partially formed glass tube 102, thereby positioning the glass tube 102 for separation of the glass article 103 from the glass tube 102 at the separating station 206. The main line 116 may also include a tube loading station 214 for feeding new length glass tubes 102 from the glass tube loading turntable 110 onto the main turntable 108. Figure 1 In one or more embodiments, the tube loading station 214 may be included in the cooling station 210. The tube loading station 214 may be located between the final forming station 204 and the separating station 206.

[0079] The forming station 204 of the main turntable 108 can form features at the first end of the glass article 103. For example, the forming station 204 can form a shoulder 142 and a flange 144 on the top (first end) of the glass article 103, which is a vial or cartridge. Once the glass article 103 is separated from the glass tube 102 at the separation station 206, the glass article 103 is transferred to the secondary processing station 112 of the secondary turntable 114. The secondary processing station 112 may include one or more forming stations 204 for forming the second end of the glass article 103, which is opposite the first end of the glass article 103. For example, the forming station 204 of the secondary processing station 112 can form one or more features at the bottom (second end) of the glass article 103.

[0080] The secondary processing station of the secondary circuit may include one or more heating stations 202, forming stations 204, polishing stations 208, cooling stations 210, unloading stations 216, or combinations of other stations or secondary processing stations 112. Although Figure 2 The secondary circuitry is depicted as having a ring-shaped arrangement of secondary processing stations 112, as previously described. However, the secondary circuitry may position the secondary processing stations 112 in other shapes, such as linear, polygonal, or other arrangements. In one or more embodiments, the secondary processing stations 112 of the secondary circuitry 118 may be used to form one or more features of the glass article 103 (e.g., vial, ampoule, cartridge, or syringe), for example, at the end of the glass article 103 opposite to the end formed by the main turntable 108. For example, in some embodiments, the glass article 103 is a vial, and the forming station 204 of the secondary circuitry 118 may form the bottom of the vial. Other features are also contemplated, such as those characteristic of ampoules, cartridges, syringes, etc. The secondary circuitry 118 may include one or more polishing stations 208 to finish the surface of the glass article. The secondary line 118 may also include multiple cooling stations 210 and unloading stations 216, at which finished glass products 103 can be unloaded from the converter 100.

[0081] The previous description of the processing station 106 of the main line 116 and the secondary processing station 112 of the secondary line 118 can be used for a typical converter 100 producing vials from glass tube 102. However, it should be understood that more or fewer processing stations 106 and secondary processing stations 112 can be used to prepare vials or other glass articles of different shapes, such as cartridges, syringes, ampoules, or other glass articles. Furthermore, it should be understood that processing stations 106 and secondary processing stations 112 can be arranged in any of a variety of different sequences and / or configurations to produce glass articles of different shapes.

[0082] Now for reference Figure 3AThe figure schematically depicts the heating station 202 of the converter 100. Each heating station 202 may include one or more heating elements 301. Figure 3A As shown, in an embodiment, the heating element 301 may include one or more burners 302, which are used at the forming station 204 ( Figure 2 The forming operation is performed at station 206 or at the separation station. Figure 2 Before performing the separation operation at point ), the target area of ​​the glass tube 102 is heated. Although Figure 3A A single burner 302 is depicted, but it should be understood that more than one burner 302 may be used in a single heating station 202. Each burner 302 may be fluidly connected to a combustion supply source 304, an oxygen supply source 306, and optionally an air supply source 308. Examples of combustion for the burner 302 may include, but are not limited to, hydrogen, hydrocarbon fuel gases such as methane, propane, and butane, other fuels, or combinations of these fuels. Each burner 302 may include a fuel control valve 310 to control the flow rate of the fuel gas to the burner 302. Each burner 302 may also include an oxygen control valve 312 to control the mass flow rate of oxygen to the burner 302. Each burner 302 may also include an air control valve 314 to optionally control the flow rate of air to the burner 302. The burner 302 combusts the fuel gas in the presence of oxygen and / or air to produce a flame that at least heats a target area of ​​the glass tube 102. Although the heating station 202 of the converter 100 is described herein as heating the glass tube 102 using a burner, it should be understood that other heating elements or methods besides a burner may also be used to heat the glass tube 102.

[0083] Now for reference Figure 3B and 3C The figure schematically depicts the forming station 204 of the converter 100. Each forming station 204 may include one or more forming tools 324, which are positioned relative to the base 104 about the tool axis E. Figure 1 Rotation. When the glass tube 102, which has been heated in the previous heating station 202, is rotated by the holder 130 when it is indexed to the forming station 204. As the glass tube 102 rotates, the forming tool 324 can engage with the outer surface 140 of the glass tube 102. The contact between the forming tool 324 and the heated outer surface 140 of the glass tube 102 can shape the glass tube 102 into the desired shape. After the contact time has elapsed, the forming tool actuator 326 retracts the forming tool 324 from engagement with the glass tube 102. Figure 3B An embodiment of a forming station 204 for forming a shoulder 142 of a glass vial formed from a glass tube 102 is illustrated. Figure 3CAn exemplary embodiment of a forming station 204' for forming a flange 144 of a glass vial formed from a glass tube 102 is schematically depicted. The forming station 204' for forming the flange 144 includes three forming tools 324a, 324b, and 324c.

[0084] Figure 3D A cooling station 210 is schematically depicted having one or more cooling nozzles 340 positioned to direct cooling fluid 342 (e.g., cold air or inert gas) toward a glass tube 102. One or more cooling nozzles 340 may be positioned to direct the cooling fluid 342 to specific regions of the glass tube 102. One or more cooling fluid control valves 344 may be fluidly connected to the cooling nozzles 340 to control the mass flow rate of the cooling fluid 342 reaching the cooling nozzles 340, which enables control of the cooling rate of the glass tube 102, as well as the temperature of the glass tube 102 and the temperature gradient within the glass tube 102.

[0085] Now for reference Figure 3E The figure schematically depicts the separation station 206 of the converter 100. Figure 3E The separation station 206 shown is a thermal separation station and is located after one or more heating stations 202 in the direction of rotation 222 of the main turntable 108. The heating stations 202 preceding the separation station 206 heat the glass tube 102 to make the glass viscous. The separation station 206 may include a separation burner 348. While the glass tube 102, which has become viscous and deformed by the previous heating station 202, rotates about the retainer axis D via the retainer 130, the separation burner 348 can engage with the outer surface 140 of the glass tube 102 to heat the glass tube 102 to a temperature at which the viscosity of the glass causes the article to separate from the glass tube 102. Once separated from the glass tube 102, the article can be transferred to the secondary turntable 114. Figure 1 (or remove from converter 100.) Figure 3E It is shown as a thermal separation station, but separation station 206 can also be a non-thermal separation station, such as a separation station using scribing and fracturing techniques, for example, as it can be used for syringes and cartridges.

[0086] Now for reference Figure 3FThe figure schematically depicts a typical through-station 212 of the converter 100. The through-station 212 is located after the separation station 206 in the direction of the rotation 222 of the main rotary table 108. As previously described, the thermal separation of article 103 from the glass tube 102 in the separation station 206 can create a meniscus 350 of glass on the working end 150 of the glass tube 102. In the through-station, the meniscus 350 is penetrated to prepare for the formation of the next article at the working end 150 of the glass tube 102. The through-station 212 may include a through-burner 352. The through-burner 352 may be located below and oriented toward the working end 150 of the glass tube 102. The through-burner 352 may be fluidly connected to one or more of a fuel gas supply source 304, an oxygen supply source 306, an air supply source 308, or a combination thereof. (The preceding text refers to...) Figure 3A The burner 302 describes the fuel gas supply source 304, the oxygen supply source 306, and the air supply source 308. When the main turntable 108 rotates the glass tube 102 to the through position 212, the flame from the through burner 352 heats the meniscus 350 of the glass and melts the meniscus 350 to penetrate the meniscus 350 of the glass and reopens the working end 150 of the glass tube 102.

[0087] Figures 3A-3F The diagram includes several different examples of processing stations 106 that can be used in converter 100. However, it should be understood that other processing stations 106 with different structures, combinations of structures, or functions can also be used to achieve the desired conversion of glass tube 102 to one or more glass articles.

[0088] Refer again Figure 1 and 2 During operation, the main rotary table 108 rotates the glass tube 102, which is fixed in the retainer 130, to the processing station 106. Specific operations are performed on the glass tube 102 at each processing station 106, such as heating, forming, penetration, separation, cooling, descent, and feeding. As used herein, the “dwell time” of the converter 100 refers to the time spent by the glass tube 102 in a particular processing station 106 before it is rotated by the main rotary table 108 to the next subsequent processing station 106. The converter 100 can be adjusted so that all processing stations 106 complete their operations within the dwell time. At the end of the dwell time, the main rotary table 108 rotates the glass tube 102 to the next processing station 106. As used herein, the “rotation time” refers to the time taken by the main rotary table 108 to rotate the glass tube 102 from one processing station 106 to the next, and is measured in units of time. As used in this disclosure, the total time for each component at each workstation is the sum of the dwell time and the rotation time.

[0089] Examples of converters 100 for converting glass tubes 102 into glass vials include a vial forming machine, model RP16, manufactured by AMBEG Dr. J. Dichter, which has an automatic tube feeder and includes 16 processing stations 106 and 8 secondary processing stations 112 in a main rotary table 116. Other examples include a vial forming machine, model RP32, manufactured by AMBEG Dr. J. Dichter, which has 32 processing stations 106 in the main line 116 and two secondary lines 118, each with 8 secondary processing stations 112; and a vial forming machine, Zeta 098, manufactured by Euromatic SRL, which has 36 processing stations. Another example may include a cartridge forming machine, Zeta 103, manufactured by Euromatic S.RL, which is a converter for converting glass tubes into cartridges. The cartridge converter has similar characteristics to the aforementioned vial converter 100, but is used to produce glass products with a cartridge forming factor rather than vials.

[0090] Although described in the context of a converter 100 for producing glass vials from glass tube 102, it should be understood that the converter 100 can be configured to produce one or more other articles, such as cartridges, syringes, ampoules or other glass articles, by changing the sequence or configuration of the processing stations 106 in the main turntable 116 or the secondary processing stations 112 in one or more secondary lines 118 and / or the forming tools 324.

[0091] Refer again Figure 1 and 2 During the conversion process, glass tube 102 is loaded into converter 100 at room temperature (approximately 23°C), but the temperature can rise to over 200°C during the consumption of glass tube 102. The temperature variation of glass tube 102 during consumption is at least partly due to heat released by burner 302 and other heat sources on converter 100. The temperature can also vary due to changes in the gas flow rate through glass tube 102 as the length of glass tube 102 decreases. As previously mentioned, the temperature variation of glass tube 102 during processing and consumption can cause dimensional and appearance variations in the glass articles formed during the conversion process. These temperature variations in the glass tube, and the resulting dimensional and appearance variations, can limit the operating window of the conversion process, reduce process capacity (Cpk), and decrease production output.

[0092] The system and method disclosed herein aim to increase or decrease the heating amount at the working end 150 of the glass tube 102 based on the article number corresponding to the working end 150 of the glass tube 102, thereby reducing temperature changes in the glass tube 102 and reducing the resulting dimensional and appearance changes in articles produced from the glass tube 102. Reference Figure 4 The figure schematically depicts the length of the glass tube 102 before the conversion. The glass tube 102 has an initial length L. T The outer diameter OD, inner diameter ID, and glass thickness T are specified. The glass tube 102 can be divided, or conceptually divided, into multiple continuous segments 146, each segment 146 having a length L. S The length L S A single article can be formed from the continuous segments 146. Each of the plurality of continuous segments 146 may correspond to an article and may be associated with an article number. The article number may be an integer from 1 to n, where 1 corresponds to the first article manufactured by the glass tube 102, and n corresponds to the last article manufactured by the glass tube 102 and the total number of articles that can be manufactured by the glass tube 102. For each successive article manufactured by the glass tube, the article number may be shifted by 1, from article number 1 to article number n. After the glass tube 102 passes through the processing station 106 on the converter 100, a glass article is formed, and the article number at the working end 150 of the glass tube 102 is incremented by 1. After article n is formed, the glass tube 102 is consumed, and another glass tube 102 may be loaded into the holder 130.

[0093] As previously stated, the temperature of the glass tube 120 can be gradually changed as the glass tube 102 is consumed with each revolution of the main turntable 108 of the converter 100. Therefore, the temperature of the glass tube 120 can vary depending on the product number at the working end 150 of the glass tube 102. This temperature variation can cause a viscosity change in the heated glass of the glass tube 102 during heating and forming, which can lead to dimensional and appearance variations. The dimensional changes of the glass products manufactured from the glass tube 102 are proportional to the temperature changes of the glass tube 102.

[0094] refer to Figure 5 The diagram illustrates how the parameters (y-axis) indicating the dimensions of the article manufactured from glass tube 102 vary according to the article number (x-axis). For example... Figure 5 As shown, the dimensions of finished products change rapidly in the first 10 to 15 products manufactured from newly loaded glass tubes. This abrupt change in the dimensions of at least a portion of the finished products in the first 10 to 15 products can be attributed to temperature variations in the glass tube during this period. For higher product numbers, the dimensional variation decreases. However, the dimensional variation in the first few products produced from the glass tube can lead to these products being non-compliant. Rejecting these non-compliant products reduces the yield from glass tube to finished product.

[0095] As previously described, the systems and methods of this disclosure are intended to adjust the heating of the glass tube 102 in one or more heating stations 202 of the converter 100 based on the article number at the working end 150 of the glass tube 102, thereby reducing the temperature variation of the glass tube 102 during its consumption in the converter 100. The heating of the glass tube 102 can be adjusted by changing the burner residence time of the burner 302 engaged with the glass tube 102 at one or more heating stations 202, changing the heating rate of the burner 302 at one or more heating stations 202, changing the exhaust flow rate near one or more heating stations 202, or a combination thereof. The heating of the glass tube 102 can be adjusted based on the article number on a per-article and / or per-rotation basis (e.g., each rotation of the main rotary table 108 of the converter 100). When on a per-article basis, the heating amount is adjusted based on the article number at each rotation of each main rotary table 108 of the converter 100. The heating amount is adjusted at the beginning of each revolution of the main turntable 108 and maintained during the entire revolution.

[0096] refer to Figure 6 The figure schematically depicts a heating station 202 of a converter 100 according to one embodiment of the present disclosure. A system of the present disclosure for producing multiple articles from a glass tube 102 may include a converter 100. The converter 100 may include multiple processing stations 106, including at least one heating station 202, at least one forming station 204, and a separating station 206. The converter 100 may be used to transpose the glass tube 106 through the multiple processing stations 106. The converter 100 may have any other features or characteristics described above with respect to the converter 100. The system may also include a system controller 400 communicatively connected to the converter 100, the system controller 400 including a processor 402 and a storage medium 404 containing computer-readable and executable instructions 406. The system controller 400 may be used to track article numbers at the working end 150 of the glass tube 102 and adjust the heating of the glass tube 102 in the heating station 202 based on the article numbers at the working end 150 of the glass tube 102. When processor 402 executes computer-readable and executable instructions 406, these instructions 406 enable system controller 400 to automatically track the product number at the working end 150 of glass tube 102. (As mentioned above...) Figure 4The product number can be an integer corresponding to a consecutive segment 146 in the glass tube 102 of initial length, wherein each consecutive segment corresponds to one product. When the processor 402 executes machine-readable and executable instructions 406, these instructions 406 can further cause the system controller 400 to increase or decrease the heating amount of the working end 150 of the glass tube 102 based on the product number at the working end 150 of the glass tube 102. The heating of the working end 150 of the glass tube 102 can be increased or decreased by changing the burner residence time in one or more heating stations 202, changing the heating rate of the burner 302 in one or more heating stations 202, changing the exhaust flow rate near one or more heating stations 202, or a combination thereof. The heating of the glass tube 102 can be increased or decreased at a single heating station 202 or multiple heating stations 202.

[0097] Refer again Figure 6 The heating of the glass tube 102 can be increased or decreased accordingly by increasing or decreasing the burner residence time in heating station 202. As previously mentioned, burner residence time refers to the duration for which the flame of burner 302 engages with the glass tube 102 to heat it. Increasing or decreasing the heating amount at the working end 150 of the glass tube 102 may include increasing or decreasing the burner residence time of the glass tube 102 engaged with the burner 302 in the at least one heating station 202, based on the product number at the working end 150 of the glass tube 102. Based on the product number at the working end 150 of the glass tube 102, the burner residence time may be increased or decreased in one or more heating stations 202.

[0098] The burner residence time can be increased or decreased by adjusting the time during which the burner 302 is moved to engage or disengage with the glass tube 102. Engagement of the burner 302 with the glass tube 102 can refer to placing the burner 302 in a position where the flame from the burner 302 extends toward or contacts the glass tube 102 to heat it. Conversely, when the burner 302 is not engaged with the glass tube 102, the burner 302 is placed in a position where the flame from the burner 302 is directed away from the glass tube 102, so that the flame does not contact or directly heat the glass tube 102. When the burner 302 is not engaged with the glass tube 102, some heat transfer from the burner 302 to the glass tube 102 may still occur, but this heating is minor and minimal compared to the heating of the glass tube 102 when the burner 302 is engaged.

[0099] refer to Figure 7A and 7BIn an embodiment, the burner 302 in the heating station 202 may be a rotary burner 330, which is operable to pivot laterally about axis F (e.g., according to...). Figure 6 The coordinate axes (in the XY plane) are configured to engage with and not engage with the glass tube 102. The rotary burner 330 may include a rotary burner actuator 332 operatively connected to the rotary burner 330. The rotary burner actuator 332 can pivot about axis F to rotate the burner 330, thereby moving the flame of the rotary burner 330 to engage with and not engage with the glass tube 102. The rotary burner actuator 332 can be communicatively connected to the system controller 400, for example, in electrical communication with the system controller 400. The rotary burner actuator 332 can be used to receive control signals from the system controller 400, wherein the control signals can cause the rotary burner actuator 332 to pivot the rotary burner 330 to engage or not engage with the glass tube 102.

[0100] The rotary burner 300 can be pivoted to engage with or not engage with the working end 150 of the glass tube 102. (Reference) Figure 7A The rotary burner 330 is shown in a position where its flame engages with the glass tube 102 to heat the glass tube 102. In this engagement position, the flame of the rotary burner 330 may contact or point towards the glass tube 102. In an embodiment, in the engagement position, the rotary burner 330 and the flame may be aligned along a line G extending through the axis of rotation D of the glass tube 102. Figure 7B A rotary burner 330 is depicted in a position where its flame is not engaged with the glass tube 102. In this non-engaged position, the flame of the rotary burner 330 can be directed away from the glass tube 102, such that the flame does not touch or directly points towards the glass tube 102. In an embodiment, when not engaged, the rotary burner 330 can be oriented so as not to align with a line G that intersects the axis of rotation D of the glass tube 102.

[0101] In one embodiment, the rotary burner actuator 332 is operable to switch the rotary burner 330 between a position engaged with the glass tube 102 and a position not engaged with the glass tube 102. In other words, the rotary burner actuator 332 can pivot the rotary burner 330 to engage or disengage with the glass tube 102. In another embodiment, the rotary burner 330 may normally be in the position engaged with the glass tube 102, and the rotary burner actuator 332 may be used to pivot the rotary burner 330 to disengage from the glass tube 102. Alternatively, the rotary burner 330 may normally be disengaged from the glass tube 102, and the rotary burner actuator 332 may be operable to pivot the rotary burner 330 to engage with the glass tube 102.

[0102] refer to Figure 7A During the operation, glass tube 102 can be rotated into heating station 202. Glass tube 102 can be a new glass tube with a product number of 1 at the working end 150; or glass tube 102 can be a partially consumed glass tube with a product number greater than 1. At time T1, rotary burner 330 can be rotated to a position engaging with glass tube 102. In an embodiment, time T1 can be equal to the time when the rotation of converter 100 ends, which is the time when glass tube 102 is fully rotated into heating station 202. For example, rotary burner 330 can be rotated during the rotation of converter 100 or simultaneously with the glass tube 102 being fully rotated into heating station 202 (e.g., reaching a stationary position in heating station 202). Figure 7A The engagement position is such that as soon as the glass tube 102 reaches a stationary position in the heating station 202, the flame of the rotary burner 330 contacts and heats the glass tube 102. Alternatively, in an embodiment, time T1 may occur after the glass tube 102 has been fully rotated into the heating station 202.

[0103] During the duration of the burner residence time (the time between T1 and T2), the rotary burner 330 can remain engaged with the glass tube 102. Time T2 is the end of the burner residence time, at which time the rotary burner 330 can pivot to disengage from the glass tube 102 to stop heating the glass tube 102, as... Figure 7B As shown. As previously described, the target burner residence time of glass tube 102 can be determined based on the product number at the working end 150 of glass tube 102. By changing the timing at which the rotary burner 330 pivots to engage or disengage with the working end 150 of glass tube 102, the burner residence time of glass tube 102 in heating station 202 can be adjusted. Based on the product number at the working end 150 of glass tube 102, time T1 and / or time T2 can be adjusted to increase or decrease the burner residence time.

[0104] After each rotation of the main rotary table 108 of the converter 100, the burner dwell time can be adjusted based on the product number at the working end 150 of the glass tube 102. In other words, the burner dwell time can be adjusted based on the product number of each successive glass tube 102 rotated to the heating station 202. Therefore, the product number at the working end 150 of each glass tube 102 can be tracked individually, allowing the burner dwell time to be adjusted independently of all other glass tubes 102 for each product of each glass tube 102. Adjusting the burner dwell time based on the product number of the glass tube 102 at each rotation of the converter 100 allows for random replacement of a new glass tube 102 whenever it is completely consumed, without having to load those new glass tubes 102 in a sequential order.

[0105] In these embodiments, the burner residence time can be adjusted based on the product number at the working end 150 of the glass tube 102, on a basis of each revolution of the main turntable 108 of the converter 100. In these embodiments, once consumed, each glass tube 102 can be directly and continuously (one after another) replaced with a new length of glass tube 102, such that during the same revolution of the main turntable 108, all holders 130 of the main turntable 108 are loaded with a new length of glass tube 102. When new glass tubes 102 are loaded sequentially, the product number at the working end 150 of the glass tube 102 will be the same for all glass tubes 102 that rotate through the heating station 202 during a single revolution. Therefore, in these embodiments, the burner residence time can be increased or decreased once per revolution of the converter 100 based on the product number at the working end 150 of the glass tube 102. New lengths of glass tubes 102 can be secured in each glass tube holder in a continuous sequence, starting with the first glass tube. In response to a change in the product number at the working end 150 of the first glass tube 102 at the at least one heating station 202, the burner dwell time at the working end 150 of the first glass tube 102 can be adjusted based on the product number, and the burner dwell time can be maintained between the glass tubes 102 at the heating station 202 until the first glass tube returns to the heating station 202 and the product number at the working end 150 of the first glass tube changes.

[0106] Refer again Figure 7A and 7BThe system may include computer-readable and executable instructions 406 such that, when the processor 402 executes the instructions, the system controller 400 may determine the article number corresponding to the working end 150 of the glass tube 102, and, based on the article number at the working end 150 of the glass tube 102, automatically increase or decrease the burner dwell time at the working end 150 of the glass tube 102 by pivoting the rotary burner 330 to engage or disengage with the working end 150 of the glass tube 102. At time T1, the system controller 400 may send a first control signal to the rotary burner 330 or the rotary burner actuator 332 to cause the rotary burner 330 or the rotary burner actuator 332 to switch the rotary burner 330 to engage with the glass tube 102. At the end of the burner dwell time at time T2, the system controller 400 may send a second control signal to the rotary burner 330 or the rotary burner actuator 332, the second control signal indicating a command to switch the rotary burner 330 to a position not engaged with the glass tube 102.

[0107] Although Figure 7A and 7B The illustration shows a rotary burner 330 that pivots about axis F to move the flame to engage or disengage with the glass tube 102; however, it should be understood that other mechanisms for moving the burner 302 to engage or disengage with the glass tube 102 are also contemplated. In embodiments, the heating station 202 may include a translation system for linearly translating the burner 302 to engage or disengage with the glass tube 102. For example, the translation system may include a track and a burner bracket engaged with the track, which can be translated along the track to move the burner 302 to engage or disengage with the glass tube 102. The translation system may also include one or more linear actuators, such as pistons, that can switch the burner 302 to engage or disengage with the glass tube 102.

[0108] Heating station 202 is described herein in the context of burner 302 for heating glass tube 102. However, it should be understood that other heating elements may also be used to heat the glass tube. Other heating elements may include, but are not limited to, lasers (e.g., CO2 lasers), induction heaters, other heating devices, or combinations thereof. The laser heating element can be turned on and off to engage or disengage the heating element from the glass tube 102.

[0109] Now for reference Figure 8 It depicts the effect of adjusting the burner residence time based on the article number at the working end 150 of the glass tube 102 on the dimensional changes of glass articles manufactured from the glass tube 102. Figure 8The diagram illustrates how the parameter (y-axis) indicating the specific dimensions of the glass articles varies according to the article number (x-axis). Line 502 corresponds to converter operation without supplemental heating of the glass tube 102. Line 502 shows the average dimension of the glass articles for each article number, where the average dimension for each article number is the average of all 16 articles with the same article number produced by the converter with 16 processing stations in the main rotary table during one revolution. Figure 8 As shown, when no supplemental heating is provided to the glass tube 102, the dimensions of the products can vary significantly from the first product to the nth product (the 29th product). Specifically, as the temperature of the glass tube 102 increases, the dimensions of the glass tube 102 change drastically in the first few products. For a few more products, the dimensions reach equilibrium, and then, at product numbers greater than 12, the dimensions change rapidly again. This is because the decrease in the total length of the glass tube 102 leads to an increase in the gas flow rate through the glass tube 102.

[0110] Figure 8 Line 504 corresponds to data generated by a converter operating at a heating station 202 with a fixed supplemental heating duration, the supplemental heating being provided by a rotary burner with a constant residence time. As indicated by line 504, providing supplemental heating with a constant, fixed duration can result in dimensional deviations in glass articles compared to operation of the converter 100 without supplemental heating. It is not intended to be bound by any particular theory that this is due to a general temperature increase at the working end 150 of the glass tube 102, which may reduce the viscosity of the glass, leading to dimensional deviations. Such dimensional deviations resulting from supplemental heating with a constant residence time can yield non-standard articles. However, this demonstrates that changing the amount of heat in heating station 202 can change the dimensions of articles produced from the glass tube 102.

[0111] Figure 8Line 506 corresponds to the operation of converter 100, in which a rotary burner 330 is installed in a processing station 106 that previously did not have a burner, and for each glass tube 102 rotated into processing station 106, the burner dwell time is adjusted based on the article number at the working end 150. For line 506, the burner dwell time is adjusted each time converter 100 rotates (e.g., based on the article). As shown by line 506, adjusting the burner dwell time based on the article number at the working end 150 of the glass tube 102 reduces dimensional variations. Moreover, adjusting the burner dwell time based on the article number at the working end 150 of the glass tube 102 does not cause dimensional deviations from the target dimensions. Similar results can be shown by replacing the stationary burner in heating station 202 with a rotary burner 330 and changing the burner dwell time. By further strengthening and improving the model, algorithm, and procedure for controlling the adjustment of dwell time, dimensional variations with respect to line 506 can be further reduced.

[0112] In this embodiment, compared to a conversion process that does not adjust the heating amount based on the product number, by adjusting the heating of the glass tube 102 based on the product number at the working end 150 of the glass tube 102, the variation in the position or size of the features of the product produced by the glass tube 102 can be reduced to less than 0.5 mm, less than 0.4 mm, less than 0.3 mm, or even less than 0.2 mm. In this embodiment, compared to a conversion process that does not adjust the heating amount based on the product number, by adjusting the heating of the glass tube 102 based on the product number at the working end 150 of the glass tube 102, the variation in the position or size of the features of the product produced by the glass tube 102 can be reduced by at least 50%, at least 60%, at least 70%, or even at least 80%.

[0113] Refer again Figure 6The heating rate in heating station 202 can be increased or decreased accordingly by increasing or decreasing the product number at the working end 150 of glass tube 102, thereby increasing or decreasing the amount of heat applied to glass tube 102 in heating station 202. The heating rate in heating station 202 can refer to the amount of heat energy output per unit time of the heating element in heating station 202. As previously mentioned, the heating element in heating station 202 can be burner 302. The heating rate of burner 302 can be adjusted by changing the amount (flow rate) of one or more combustion gases introduced into burner 302. As described herein, the term "combustion gas" refers to gases, such as fuel gas, oxygen, and / or air, that pass through burner 302 as a source of combustion reactants and are burned to generate heat for heating glass tube 102. The term "combustion gas" is not intended to represent a gas stream that is generated by combustion and contains combustion reaction products. Combustion gases can include fuel gas and oxygen, air, or combinations thereof. Based on the product number at the working end 150 of the glass tube 102 at one or more heating stations 202 on the converter, the heating rate of the heating element (e.g., burner 302) can be adjusted to compensate for temperature changes in the glass tube 102 throughout the conversion process.

[0114] As previously described, heating station 202 may include one or more burners 302. Each burner 302 may be fluidly connected to a combustion supply source 304, an oxygen supply source 306, and optionally an air supply source 308. Each burner 302 may include at least one fluid control valve operated to control the flow rate, such as mass flow rate, of one or more combustion gases to the burner 302. For example, each burner 302 may be fluidly connected to a fuel control valve 310 for controlling the flow rate of fuel gas to the burner 302, an oxygen control valve 312 for controlling the mass flow rate of oxygen to the burner 302, and optionally, an air control valve 314 for optionally controlling the flow rate of air to the burner 302. The burner 302 combusts the fuel gas in the presence of oxygen and / or air to produce a flame that at least heats a target area of ​​the glass tube 102. The fuel control valve 310, oxygen control valve 312, and optional air control valve 314 may be communicatively connected to the system controller 400, for example, in electronic communication with the system controller 400. Fuel control valve 310, oxygen control valve 312, and optional air control valve 314 can each be used to receive signals from system controller 400, indicating the flow rates of fuel gas, oxygen, and air supplied to burner 302, respectively. The flow rate of each gas can be a mass flow rate, and fuel control valve 310, oxygen control valve 312, and optional air control valve 314 can be mass flow controllers. In embodiments, fuel control valve 310, oxygen control valve 312, and optional air control valve 314 may not be communicatively connected to system controller 400, but can be configured to provide a constant fuel-oxygen ratio. In these embodiments, the system may include a main combustion gas flow controller fluidly connected to burner 302 and communicatively connected to system controller 400. The main combustion gas flow controller can be operated to control the total mass flow rate of combustion gases arriving at burner 302, wherein the combustion gases have a constant fuel-to-oxygen ratio, as set by fuel control valve 310, oxygen control valve 312, and optional air control valve 314. Other configurations for various control valves for combustion gases are also envisioned for controlling the heating rate of the burner 302 in the heating station 202.

[0115] The heating rate of each burner 302 can be increased or decreased by increasing or decreasing the flow rate (e.g., mass flow rate) of one or more of the fuel gas, oxygen, air, or combinations thereof reaching the burner 302. Increasing or decreasing the heating rate of the burner 302 in the heating station 202 can include proportionally increasing or decreasing the flow rate of the combustion gases. In other words, the ratio of fuel gas to oxygen in the combustion gases introduced into the burner 302 can be kept constant, and the total flow rate of the combustion gases can be increased or decreased to increase or decrease the heating rate of the burner 302, respectively. In an embodiment, the fuel control valve 310, the oxygen control valve 312, and optionally the air control valve 314 can be operated to increase or decrease the mass flow rate of all combustion gases reaching the burner 302 while maintaining a constant fuel gas to oxygen ratio. In an embodiment, increasing or decreasing the heating rate of the glass tube 102 based on the article number at the working end 150 of the glass tube 102 can include changing the mass flow rate ratio of fuel gas to oxygen supplied to the burner 302.

[0116] Still referencing Figure 6 The system may include computer-readable and executable instructions 406, which, when executed by processor 402, cause system controller 400 to determine the article number at the working end 105 of glass tube 102 and, based on the article number at the working end 150 of glass tube 102, increase or decrease the mass flow rate of one or more combustion gases of the at least one burner 302. When processor 402 executes computer-readable and executable instructions 406, these instructions cause system controller 400 to send control signals to one or more of a fuel gas control valve 310, an oxygen control valve 312, an air control valve 314, or a combination thereof, wherein the control number indicates the position of the corresponding flow control valve to achieve the desired heating rate of burner 302. In an implementation, when the processor 402 executes computer-readable and executable instructions 406, these instructions 406 can cause the system controller 400 to send control signals to the fuel gas control valve 310, the oxygen control valve 312, and the optional air control valve 314 to increase or decrease the flow rates of fuel gas, oxygen, and optional air reaching the burner 302, while maintaining a constant fuel gas to oxygen mass flow rate ratio introduced into the burner 302.

[0117] Now for reference Figure 9This figure depicts the temperature (y-axis) of the glass tube 102 in heating station 202 as a function of time (x-axis) for a constant combustion gas flow rate (reference numeral 902) and for an increase in the combustion gas flow rate at a time equal to zero (reference numeral 904). The time equal to zero represents the end of the inversion time of the converter 100 and the moment when the glass tube 102 reaches its stationary position in heating station 202. At a constant combustion gas flow rate, the temperature of the glass tube 102 can increase with increasing residence time in heating station 202, as shown by line 902. For line 904, the flow rate of the combustion gas reaching the burner 302 in heating station 202 is gradually increased at a time equal to zero. Figure 9 As shown, the temperature response of the glass tube 102 to changes in the flow rate of the combustion gas reaching the burner 302 is delayed. After an initial change in the flow rate of the combustion gas at a time equal to zero, the temperature (904) of the glass tube 102 continues to rise at a rate that is the same as the rate of temperature rise (902) of the glass tube 102 with a constant combustion gas flow. At a residence time of approximately 0.5 seconds, the effect of changing the combustion gas flow begins to take effect, and approximately 0.5 seconds after the time equal to zero, the heating rate of the burner 302 begins to increase, as evidenced by the deviation of line 904 from line 902. After the change in the flow rate of the combustion gas, the heating rate of the burner 302 requires time to reach its final heating rate. This is in Figure 9 The temperature change slope is shown in the time interval between 0.5 seconds and approximately 0.8 seconds, during which the slope is greater than that after 0.8 seconds. This demonstrates a delay in the response of the burner 302's heating rate to changes in the combustion gas flow rate.

[0118] After each rotation of the main turntable 108 of the converter 100, the heating rate of the heating element / burner 302 in the heating station 202 can be adjusted based on the product number at the working end 150 of the glass tube 102. In other words, the heating rate of the burner 302 can be adjusted based on the product number of each successive glass tube 102 rotated into the heating station 202. Therefore, the product number at the working end 150 of each glass tube 102 can be tracked individually so that the heating rate of the heating element can be adjusted for each product of each glass tube 102 independently of all other glass tubes 102. Adjusting the heating rate based on the product number of the glass tube 102 at each rotation of the converter 100 allows new glass tubes 102 to be loaded randomly whenever a glass tube 102 is completely consumed, instead of loading those new glass tubes 102 in a consecutive sequence. However, as Figure 9As shown, the temperature of the glass tube 102 is delayed in responding to changes in the flow rate of the combustion gas reaching the burner 302, which limits the ability to change the heating rate based on each rotation to adequately compensate for the temperature change of the glass tube 102.

[0119] In some embodiments, the heating rate of the heating element or burner 302 can be adjusted based on the part number at the working end 150 of the glass tube 102 for each revolution of the main turntable 108 of the converter 100. In these embodiments, once consumed, each glass tube 102 can be directly and continuously (one after another) replaced with a new length of glass tube, such that all holders 130 of the main turntable 108 are loaded with a new length of glass tube 102 during the same revolution of the main turntable 108. In this case, the part number at the working end 150 of the glass tube 102 can be the same for all glass tubes 102 that rotate through the heating station 202 during a single revolution. Therefore, in these embodiments, the heating rate can be increased or decreased once for each revolution of the converter 100 based on the part number at the working end 150 of all glass tubes 102. New lengths of glass tubes 102 can be fixed in each glass tube holder 130 in a continuous sequence, starting with the first glass tube. In response to a change in the product number at the working end 150 of the first glass tube 102 at the at least one heating station 202, the heating rate of the burner 302 can be adjusted based on the product number at the working end 150 of the glass tube 102. Furthermore, at the heating station 202, the heating rate of the burner 302 can be maintained between the glass tubes 102 until the first glass tube returns to the heating station 202 and the product number at the working end 150 of the first glass tube changes. By changing the heating rate of the burner 302 on a rotational basis, the delay in the thermal response of the burner 302 to changes in the flow rate of the combustion gas can be reduced.

[0120] Now for reference Figure 10A This figure schematically depicts the variation of the dimensions (y-axis) of the article from the glass tube 102 with respect to the article number (x-axis) at the working end 150 of the glass tube 102 in a converter for uncompensated temperature variations of the glass tube 102. Figure 10A As shown, the average size of the products varies drastically in the first 10 to 15 products manufactured from the glass tube (the first 10 to 15 revolutions on the main turntable). This variation can lead to products that initially produce non-standard items from the glass tube, which can reduce the throughput of the conversion process and increase waste.

[0121] Now for reference Figure 10BThis figure schematically depicts the variation of the dimensions (y-axis) of the products produced by the glass tube 102 according to the product number at the working end 150 of the glass tube 102, for a converter that adjusts the heating rate of the burner 302 in the heating station 202 based on the product number at the working end 150 of the glass tube 102 per revolution. Figure 10B As shown, by adjusting the heating rate of the burner 302 in the heating station 202 based on the product number at the working end 150 of the glass tube 102 on a per-revolution basis, the dimensional variation of the products produced by the glass tube 102 can be significantly reduced, especially in the first 10 to 15 products produced by each glass tube 102. Compared to a converter with a constant burner heating rate, by adjusting the burner heating rate based on the product number on a per-revolution basis, the dimensional variation of the products can be reduced by at least 50%, at least 60%, at least 70%, or even at least 80%. Therefore, changing the heating rate of one or more burners 302 in one or more heating stations 202 based on the product number at the working end 150 of the glass tube 102 can reduce dimensional and appearance variations in the finished products.

[0122] Now for reference Figure 11 Based on the product number at the working end 150 of the glass tube 102, the heating of the glass tube 102 in the heating station 202 can also be adjusted by changing the flow rate of the exhaust gas near the heating station 202. The converter 100 may include an exhaust system 670, which may include one or more inlet vents 672 fluidly connected to an air processor 674 via a conduit 676. The air processor 674 is capable of drawing air into the inlet vents 672 and directing it through the conduit 676. Drawing air into the exhaust system through the inlet vents 672 can create a localized negative pressure in the region of the working end 150 of the glass tube 102, which can sufficiently reduce or overcome the chimney effect in the glass tube 102 to at least reduce or prevent upward gas flow through the center of the glass tube 102. Reducing or preventing upward gas flow through the glass tube 102 can reduce the effect of these gases on the temperature changes of the glass tube 102. Alternatively or additionally, changing the negative pressure near the working end 150 of the glass tube 102 can adjust the flow rate of gas through the internal volume of the glass tube 102, thereby controlling heat transfer to the non-working length of the glass tube 102. The localized negative pressure generated by the exhaust system 670 can also remove excess heat from the outside of the glass tube 102, for example, from the air surrounding the glass tube 102.

[0123] The inlet vent 672 can be positioned a distance M from the outer surface 140 of the glass tube 102 at its working end 150. The distance M can be small enough that the exhaust system 670 can generate a negative pressure at the working end 150 of the glass tube 102 sufficient to at least partially or completely overcome the chimney effect within the internal volume of the glass tube 102. However, if the distance M is too small, the inlet vent 672 may come into contact with the working end 150 of the glass tube 102 due to minute dimensional changes in the glass tube 102 and / or the converter 100 as the glass tube 102 is rotated into or out of the processing station 106. Additionally, if the distance M is too small, the inlet vent 672 may interfere with the performance of the burner, for example, the burner 302 of one of the heating stations 202.

[0124] Air processor 674 may include, but is not limited to, one or more of a blower, fan, pump, vacuum pump, other vacuum device, or air handling equipment, or a combination thereof. In embodiments, exhaust system 670 may include multiple air processors 674, and one or more processing stations 106 (e.g., heating station 202 or separation station 212) may have a dedicated air processor for that heating station 106 only. The conduit 676 connecting the air processor 674 to the inlet vent 672 may include rigid conduit, flexible conduit, or a combination of both. Flexible conduit can provide automatic adjustment of the position of the inlet vent 672 relative to the working end 150 of the glass tube 102. Because the inlet vent 672 and conduit 676 are near the heating station 106, in some embodiments, the inlet vent 672 and conduit 676 may be constructed of a heat-resistant material capable of withstanding the temperatures of heated gases and vapors generated near the glass tube 102 residing in the heating station 202.

[0125] The exhaust system 670 may optionally include a damper 680 located in duct 676, between duct 676 and air processor 674, or between duct 676 and inlet vent 672. The damper 680 may be adjustable to control airflow through the exhaust system 670, thereby controlling the negative pressure generated by the exhaust system 670 at the working end 150 of the glass tube 102. The damper 680 may include one or more of a pneumatic actuator, an electric actuator, a hydraulic actuator, an electromagnetic actuator, or other types of actuators. In some embodiments, the damper 680 may include a solenoid. The air processor 674, the damper 680, or both may be communicatively connected to the system controller 400 and may be used to receive control signals from the system controller 400 to control airflow through the exhaust system 670.

[0126] Refer again Figure 11The inlet vent 672 may be located near the heating station 202. In an embodiment, the exhaust system 670 may include a plurality of vents 672, and each vent 672 is located at at least one of the processing stations 106, for example, at the heating station 202. During operation, as previously described, the inlet vent 672 may be located near the working end 150 of the glass tube 102. The air processor 674 may generate an airflow from the inlet vent 672 to the air processor 674 via the duct 676. Air and gas adjacent to the working end 150 of the glass tube 102 may be drawn into the inlet vent 672 by the airflow through the duct 676, thereby creating a negative pressure near the working end 150 of the glass tube 102. The negative pressure may reduce or overcome the chimney effect to reduce or prevent the flow of gas or vapor through the internal volume of the glass tube 102. The airflow through the exhaust system 670 may be adjusted by changing the speed of the air processor 674 and / or changing the position of the damper 680. By changing the speed of the air processor 674, changing the position of the damper 680, changing the position of the inlet vent 672 relative to the working end 150 of the glass tube 102, or a combination of these, the negative pressure generated near the working end 150 of the glass tube 102 can be altered. Changing the negative pressure can adjust the flow rate of gas through the internal volume of the glass tube 102.

[0127] As previously described, the heating of the glass tube 102 in heating station 202 can be adjusted by changing the operation of the exhaust system 670 at heating station 202, based on the product number at the working end 150 of the glass tube 102. Increasing or decreasing the heating amount of the glass tube 102 in one or more heating stations 202 may include adjusting the negative pressure generated by the exhaust system 670 near the glass tube 102 based on the product number at the working end 150 of the glass tube 102. As previously described, adjusting the negative pressure generated by the exhaust system 670 near the glass tube 102 may include adjusting the speed of the air processor 674, adjusting the position of the air valve 680, adjusting the position of the inlet vent 672 relative to the glass tube 102, or a combination thereof. In an embodiment, increasing or decreasing the heating amount of the glass tube 102 in a heating station may include adjusting the exhaust flow rate near the at least one heating station 202 based on the product number at the working end 150 of the glass tube 102. Adjusting the exhaust flow rate may include adjusting the speed of the air processor 674 and / or adjusting the position of the air valve 680.

[0128] Refer again Figure 11The system may include computer-readable and executable instructions 406, which, when executed by processor 402, cause system controller 400 to determine the article number at the working end 105 of glass tube 102 and, based on the article number at the working end 150 of glass tube 102, automatically adjust the negative pressure generated by exhaust system 670 near glass tube 102. In an embodiment, exhaust system 670 may include air processor 674 communicatively connected to system controller 400, which, when executed by processor 402, causes system controller 400 to automatically adjust the speed of air processor 674 based on the article number at the working end 150 of glass tube 102. When processor 402 executes computer-readable and executable instructions 406, these instructions cause system controller 400 to send a control signal to air processor indicating the adjusted speed of air processor 674 in response to the article number at the working end 150 of glass tube 102.

[0129] In one embodiment, the emission system 670 may include a damper 680 communicatively connected to the system controller 400. When the processor 402 executes a computer-readable and executable instruction 406, this instruction 406 causes the system controller 400 to automatically adjust the position of the damper 680 based on the article number at the working end 150 of the glass tube 102. When the processor 402 executes the computer-readable and executable instruction 406, this instruction 406 causes the system controller 400 to send a control signal to the damper 680, indicating the position of the damper 680 in response to the article number at the working end 150 of the glass tube 102.

[0130] In one embodiment, the venting system 670 may include a vent actuator operable to translate the inlet vent 672 relative to the glass tube 102, for example, moving the inlet vent 672 closer to or further away from the glass tube 102. The vent actuator may be communicatively connected to the system controller 400, and when the processor 402 executes a computer-readable and executable instruction 406, the instruction 406 may cause the system controller 400 to automatically adjust the position of the inlet vent 672 by adjusting the position of the vent actuator based on the article number at the working end 150 of the glass tube 102. When the processor 402 executes the computer-readable and executable instruction 406, the instruction 406 may cause the system controller 400 to send a control signal to the vent actuator indicating the position of the inlet vent 672 in response to the article number at the working end 150 of the glass tube 102.

[0131] On a per-rotation basis, the negative pressure generated by the exhaust system 670 can be adjusted based on the article number at the working end 150 of the glass tube 102. However, the time lag between the change in the exhaust system 670 and the temperature of the glass tube 102 may limit the application of adjusting the exhaust system 670 on a per-rotation basis (e.g., changing the exhaust system during each rotation of the main rotary table of the converter). Alternatively, the negative pressure generated by the exhaust system 670 can be adjusted on a per-rotation basis, based on the article number at the working end 150 of the glass tube 102, wherein the negative pressure generated by the exhaust system 670 is adjusted based on the article number at the working end 150 of the glass tube 102, and maintained during one complete rotation of the main rotary table 108 of the converter 100. Changing the exhaust flow rate can also affect other aspects of the tube conversion process, such as the formation of SHR in the glass article, mechanical growth, or other factors.

[0132] Now for reference Figure 12 This figure illustrates the effect of exhaust flow rate on dimensional changes. Line 1202 represents products manufactured with zero exhaust flow. For products represented by lines 1204, 1206, and 1208, the airflow gradually increases. Figure 12 As shown, in the first five products produced by glass tube 102, increasing the airflow rate can reduce dimensional variations, as indicated by the decrease in the slope of the curve in the first five products and the decrease in the maximum difference between the maximum and minimum average dimensions in these product numbers.

[0133] As previously stated, the heating of the glass tube 102 can be adjusted at one or more heating stations 202 based on the product number at the working end 150 of the glass tube 102. Adjusting the heating of the glass tube 102 at multiple heating stations 202 can include adjusting the burner residence time, adjusting the heating rate of the heating element (e.g., burner 302), or adjusting the negative pressure or exhaust flow rate generated by the exhaust system 670 at the multiple heating stations 202 of the converter 100. Various combinations of adjusting the burner residence time, the heating rate of the burner 302, or the exhaust flow rate can also be employed at one or more heating stations 202 of the converter 100. It should be understood that any combination of these methods can be used at one or more heating stations 202 of the converter 100 to control the temperature variability of the glass tube 102 during consumption of the glass tube 102 in the conversion process. As previously stated, the burner residence time, heating rate, exhaust flow, or combinations thereof can be adjusted based on each rotation or revolution of the converter 100.

[0134] Embodiments of this disclosure may be embodied in hardware and / or software (including firmware, resident software, microcode, etc.). The system controller 400 of the converter and / or other controllers on the converter 100 may include at least one processor and a computer-readable medium (i.e., a storage module), as previously described in this specification. A computer-usable or computer-readable medium or storage module may be any medium capable of containing, storing, communicating, propagating, or transmitting programs for use by or in connection with an instruction execution system, device, or apparatus.

[0135] Computer-usable or computer-readable media or storage modules can be, for example, but not limited to, electronic, magnetic, optical, electromagnetic, infrared, or semiconductor systems, devices, apparatuses, or propagation media. More specific examples of computer-readable media (a non-exhaustive list) will include the following: electrical connections having one or more wires, portable computer floppy disks, random access memory (RAM), read-only memory (ROM), erasable programmable read-only memory (EPROM or flash memory), optical fibers, and portable read-only optical disk storage (CD-ROM). It should be noted that computer-usable or computer-readable media can even be paper or other suitable media on which a program is printed, because the program can be obtained electronically, for example by optical scanning of paper or other media, and then compiled, interpreted, or processed in an appropriate manner (if necessary), and then stored in computer memory.

[0136] Computer-readable media may include machine-readable and executable instructions for performing the operations of this disclosure. These machine-readable and executable instructions may include computer program code, which, for ease of development, may be written in a high-level programming language (e.g., C or C++). Furthermore, the computer program code for performing the operations of this disclosure may also be written in other programming languages, such as, but not limited to, interpreted languages. Some modules or routines may be written in assembly language or even microcode to enhance performance and / or memory utilization. However, the software implementation of this disclosure is not dependent on the use of a particular programming language. It should also be understood that the functionality of any or all program modules may also be implemented using discrete hardware components, one or more application-specific integrated circuits (ASICs), or a programmed digital signal processor or microcontroller.

[0137] Refer again Figure 6A method for producing multiple articles from a glass tube 102 may include: securing a working end 150 of the glass tube 102 in a glass tube holder 130 of a converter 100 having multiple processing stations 106. The multiple processing stations 106 may include at least one heating station 202 and at least one forming station 204 disposed after said at least one heating station 202. The converter 100 may rotate the glass tube holder 130 through the multiple processing stations 106. The method may further include: rotating the glass tube 102 through each of the multiple processing stations 106. The initial length of the glass tube 102 may include multiple continuous segments 146. In other words, the glass tube 102 can conceptually be divided into a series of continuous segments 146. Each of the multiple continuous segments 146 may correspond to an article, and each article may have an article number. The product number can be an integer, starting from 1 at the initial working end of the glass tube and increasing by 1 for each successive segment 146 until the product number n at the non-working end of the glass tube 102, where n is the total number of products that can be produced from a single length of glass tube 102.

[0138] The method may further include heating the working end 150 of the glass tube 102 at the at least one heating station 202. The method may include forming at least one feature of an article at the working end 150 of the glass tube 102 at the at least one forming station 204, separating the article from the working end 150 of the glass tube 102 at a separating station 206, and downwardly rotating the glass tube 102 in a glass tube holder 130 to form a subsequent article. Downward rotation of the glass tube 102 may occur before or after separating the article from the working end 150 of the glass tube 102. The method may include increasing or decreasing the heating amount of the glass tube 102 based on the article number corresponding to the working end 150 of the glass tube 102. Increasing or decreasing the heating amount of the glass tube 102 based on the article number can reduce the variation in tube temperature and / or article size between one article number and the next article number. The variation in tube temperature and / or article size at the working end 150 of the glass tube 102 may vary depending on the article number of the article formed at the working end 150 of the glass tube 102. The article may be a pharmaceutical container, such as, but not limited to, vials, cartridges, syringes, ampoules, or other pharmaceutical containers.

[0139] Increasing or decreasing the heating amount of the glass tube 102 may include at least one of the following: increasing or decreasing the burner residence time of the working end 150 of the glass tube 102 in contact with the heating element (e.g., burner 302) in the at least one heating station 202 based on the product number at the working end 150 of the glass tube 102; increasing or decreasing the heating rate of the heating element or burner 302 in the at least one heating station 202 based on the product number at the working end 150 of the glass tube 102; or adjusting the negative pressure or exhaust flow rate near the glass tube 102 in the at least one heating station 202 and generated by the exhaust system 670 based on the product number at the working end 150 of the glass tube 102.

[0140] In one embodiment, the plurality of processing stations 106 may include a plurality of heating stations 202, and the method may include: increasing or decreasing the heating amount of the glass tube 102 (e.g., the working end 150 of the glass tube 102) in each of the plurality of heating stations 202 based on the product number corresponding to the working end 150 of the glass tube 102. In another embodiment, the method may include: increasing or decreasing the heating amount of the glass tube 102 (e.g., the working end 150 of the glass tube 102) in each of the plurality of heating stations 202 based on the product number corresponding to the working end 150 of the glass tube 102.

[0141] refer to Figure 7A and 7B In one embodiment, increasing or decreasing the heating amount of the glass tube 102 may include increasing or decreasing the burner dwell time of the glass tube 102 in contact with a heating element (e.g., burner 302) in the at least one heating station 202, based on the article number at the working end 150 of the glass tube 102. The heating element in the at least one heating station may include a rotary burner 330, which may pivot to engage or disengage with the working end 150 of the glass tube 102. In one embodiment, the rotary burner 330 may include a rotary burner actuator 332, and the method may include actuating the rotary burner actuator 332, wherein actuation of the rotary burner actuator 332 may pivot or move the rotary burner 330 to engage or disengage with the working end 150 of the glass tube 102, thereby adjusting the burner dwell time. In one embodiment, increasing or decreasing the burner dwell time may include adjusting the time for the rotary burner 330 to pivot to engage or disengage with the working end 150 of the glass tube 102.

[0142] Refer again Figure 6In one embodiment, increasing or decreasing the heating amount at the working end 150 of the glass tube 102 may include: increasing or decreasing the heating rate of the heating element in the at least one heating station 202 based on the product number of the working end 150 of the glass tube 102. In another embodiment, the heating element may include a burner 302 or a rotary burner 330, and increasing or decreasing the heating rate may include: increasing or decreasing the flow rate of one or more combustion gases supplied to the burner 302 or the rotary burner 330. The combustion gases may include fuel gas and oxygen and / or air. In another embodiment, increasing or decreasing the heating rate of the burner 302 or the rotary burner 330 in the at least one heating station 202 may include: proportionally increasing or decreasing the flow rate of all combustion gases reaching the burner 302 or the rotary burner 330. The method may include: maintaining a constant mass flow ratio of fuel gas to oxygen for the combustion gases delivered to the burner 302 or the rotary burner 330. In an embodiment, increasing or decreasing the heating rate of the burner 302 or rotary burner 330 in the at least one heating station 202 may include changing the flow ratio of fuel gas to oxygen supplied to the burner 302 or rotary burner 330.

[0143] Refer again Figure 11 In one embodiment, increasing or decreasing the heating amount at the working end 150 of the glass tube 102 may include: adjusting the negative pressure or exhaust flow rate generated by the exhaust system 670 near the glass tube 102 in the at least one heating station 202 based on the product number of the working end 150 of the glass tube 102. In another embodiment, adjusting the negative pressure or exhaust flow rate near the glass tube 102 in the at least one heating station 202 may include: increasing or decreasing the speed of the air processor 674 fluidly connected to the inlet vent 672, which is located near the at least one heating station 202; and / or adjusting the position of the damper disposed between the air processor 674 and the inlet vent 672. Alternatively or additionally, in another embodiment, adjusting the negative pressure or exhaust flow rate near the glass tube 102 in the at least one heating station 202 may include: adjusting the position of the inlet vent 672 of the exhaust system 670 relative to the glass tube 102 in the at least one heating station 202.

[0144] refer to Figure 1 and Figure 6In an embodiment, the converter 100 may include a plurality of glass tube holders 130, and the method may include: transposing each of the plurality of glass tube holders 130 through each of a plurality of processing stations 106, and, each time the plurality of glass tube holders 130 are transposed between the processing stations 106, increasing or decreasing the amount of heating at the working end 150 of the glass tube 102 at the at least one heating station 202 based on the article number of the working end 150 of the glass tube 102.

[0145] The method may include securing a new length of glass tube 102 in a tube holder 130 after the production of a final product corresponding to the final product number n of the glass tube 102. In an embodiment, the converter 100 may include a plurality of glass tube holders 130, and the method may further include securing a new length of glass tube 102 in each of the plurality of tube holders 130 in a sequential order, starting with a first glass tube. In other words, the method may include replacing the glass tubes 102 in the glass tube holders 130 one by one. In response to a change in the product number at the working end 150 of the first glass tube at the at least one heating station 202, the method may further include changing the heating amount at the working end 150 of the first glass tube based on the product number, and maintaining the heating amount at the at least one heating station 202 between glass tubes 102 until the first glass tube returns to the at least one heating station 202 and the product number at the working end 150 of the first glass tube changes.

[0146] Refer again Figure 1 and 6A method for producing multiple articles from a glass tube 102 may include: introducing the glass tube 102 into a glass tube holder 130 of a converter 100 having a plurality of processing stations 106. The plurality of processing stations 106 may include at least one heating station 202 and at least one forming station 204 disposed after the at least one heating station 202. The converter 100 may rotate the glass tube holder 130 through the plurality of processing stations 106. The method may include: heating a working end 150 of the glass tube 102 at the at least one heating station 202; and forming at least one feature of a first article at the working end 150 of the glass tube 102 at the at least one forming station 204. The first article may correspond to a first consecutive position along a length L of the glass tube 102. The method may include: separating a first article from the working end 150 of a glass tube 102 at a separation station 106 located after forming station 204, and rotating the glass tube 102 downward in a glass tube holder 130 to form a second article from the glass tube 102. The second article may correspond to a second consecutive position along the length L of the glass tube 102. The glass tube 102 may be rotated downward before or after separation. The method may include: heating the working end 150 of the glass tube 102 corresponding to the second consecutive position at at least one heating station 202; and increasing or decreasing the amount of heating of the working end 150 of the glass tube 102 relative to the heating of the first article, corresponding to the second consecutive position. Increasing or decreasing the amount of heating of the working end 150 of the glass tube 102 relative to the first article for the second article may reduce the temperature or dimensional variability of the second article relative to the first article. The heating of the glass tube 102 may be increased or decreased according to any of the methods or techniques described above.

[0147] Example

[0148] The following embodiments illustrate the operation of the disclosed system and method for producing multiple glass articles from a glass tube in a converter. These embodiments are not intended to limit the scope of this disclosure.

[0149] The following examples illustrate the use of the disclosed system and method for reducing dimensional and appearance variations in articles made from glass tubes, which is achieved by reducing the temperature change of the glass tube during the conversion process as it is gradually consumed. The glass tubes in these examples are aluminosilicate glass tubes, such as VALOR manufactured and sold by Corning Incorporated. TM Glass. After conversion, aluminosilicate glass tubes can be further processed by annealing and / or ion exchange.

[0150] Burner residence time – Comparative Examples 1 and 2 and Example 3

[0151] For Comparative Examples 1 and 2 and Example 3, the effect of burner residence time on the dimensional changes of glass articles made from glass tubes was investigated. An aluminosilicate glass tube was converted into a glass vial using a converter. The aluminosilicate glass tube was a VALOR manufactured by Corning Incorporated. TM Glass tubes. The converter used was a vial forming machine, model RP16, manufactured by AMBEG Dr.J.Dichter, with an automatic tube feeder, comprising 16 processing stations in the main line and 8 secondary processing stations in the secondary line. Table 1 below provides a description of the processing stations in the main line of the converter used in Example 1.

[0152] Table 1: Description of the processing stations of the converter in Example 1

[0153]

[0154] For Comparative Example 1, glass vials were produced without adding supplemental heating to the converter. For Comparative Examples 2 and 3, a rotary burner was installed in processing station A2. For Comparative Example 2, glass vials were produced with supplemental heating of a fixed duration in processing station A2. The fixed-duration supplemental heating in Comparative Example 2 was provided by a rotary burner with a constant residence time in processing station A2. For Example 3, while producing glass vials, the burner residence time of the rotary burner in Comparative Example 2 was changed based on the product number at the working end of the glass tube. In Comparative Examples 1 and 2 and Example 3, the mass flow rate of the combustion gas arriving at the burner was maintained constant, thus keeping the heating rate of the burner constant. Only the duration of contact between the burner flame and the glass tube was changed.

[0155] A total of 16 tubes are loaded into the converter. Therefore, for each product number, each converter revolution produces 16 products. Figure 8 The illustration shows the variation of specific product dimensions (y-axis) with respect to product number (x-axis). Data from Comparative Example 1 is depicted as circles, and line 502 represents the average of all 16 products for each product number. Data from Comparative Example 2 is depicted as triangles, and line 504 represents the average of all 16 products for each product number. Data from Example 3 is depicted as squares, and line 506 represents the average of all 16 products for each product number in Example 3.

[0156] like Figure 8As shown, for Comparative Example 1 (line 502), the dimensions of the products varied significantly from the first product to the nth product (the 29th product). Specifically, as the temperature of the glass tube increased, the dimensions of the products changed drastically in the first few products. For a few more products, the dimensions reached equilibrium, and then, at product numbers greater than 12, the dimensions changed rapidly again. Due to the fixed amount of heating added in Comparative Example 2 (line 504), the dimensions of the products deviated somewhat from those produced in Comparative Example 1. However, as the glass tube heated, the significant dimensional changes in the first 5 or 6 vials followed the same general trend, followed by additional dimensional changes after product 12. It is not intended to be bound by any particular theory that this is due to the temperature change of the glass tube during multiple rotations of the converter, which can alter the viscosity of the glass tube and lead to dimensional deviations. However, Comparative Example 2 demonstrates that changing the amount of heating alters the dimensions of the vials produced from the glass tube.

[0157] In Example 3 (line 506), the heating amount is adjusted based on the product number at the working end of the glass tube, on a per-rotation basis. As shown in line 506, adjusting the heating amount based on the product number at the working end of the glass tube reduces the dimensional variation of the glass products produced from the glass tube. Specifically, for line 506, significant dimensional variations of the glass tube in the first 5 products can be greatly reduced and / or eliminated. Adding the adjustment of the heating amount based on the product number of Example 3 reduces the dimensional variation of the glass products to about one-third or even less than one-third of the dimensional variation of Comparative Example 1 without adjusted heating amount. It is not intended to be bound by any particular theory, but it is thought that further reduction in dimensional variation in Example 3 can be achieved by further enhancing the control algorithm for tracking the product number and adjusting the burner residence time based on the product number.

[0158] Heating rate – Comparative Example 4 and Example 5.

[0159] In Comparative Examples 4 and 5, the effect of adjusting the heating rate of the burner in the heating station based on the article number at the working end of the glass tube on the dimensional changes of glass articles manufactured from the glass tube was investigated. The aluminosilicate glass tube was converted into a glass vial using the converter described in Comparative Example 1. For Comparative Example 4, the heating rate of the burner in the heating station was kept constant by maintaining a constant mass flow rate of the combustion gases (fuel and oxygen) reaching the burner at a constant fuel-to-oxygen ratio. For Example 5, the heating rate of the burner was adjusted based on the article number at the working end of the glass tube, increasing or decreasing the mass flow rate of the combustion gases at a constant fuel-to-oxygen ratio.

[0160] Figure 9The temperature variation of the glass tube in the heating station over time is shown for Comparative Example 4 and Example 5. Figure 9 In this context, the time equal to zero represents the end of the transposition time of the converter 100 and the moment when the glass tube 102 reaches its stationary position in the heating station 202. In Comparative Example 4 (line 902), under a constant combustion gas flow rate, the temperature of the glass tube increases with time. For Example 5 (line 904), the flow rate of the combustion gas reaching the burner in the heating station is gradually increased at the time equal to zero. Figure 9 As shown, a delay was observed in the temperature response of the glass tube in response to changes in the flow rate of the combustion gases reaching the burner. After the initial change in the flow rate of the combustion gases, which was equal to zero at time, the temperature of the glass tube in Example 5 (904) continued to rise at a rate similar to that of the glass tube in Comparative Example 4 (902). Approximately 0.5 seconds after the change in the burner's heating rate, the effect of the change in the combustion gas flow rate began to take effect, and the temperature of the glass tube rose, as evidenced by the deviation of line 904 from line 902 approximately 0.5 seconds after the time equal to zero. After the change in the flow rate of the combustion gases, the heating rate of burner 302 required time to reach its final heating rate. This is evident in... Figure 9 The data is presented using a time interval between 0.5 seconds and approximately 0.8 seconds, during which the slope of the temperature change is greater than that after 0.8 seconds. This demonstrates a delay in the response of the glass tube's temperature to changes in the flow rate of the combustion gases.

[0161] Figure 10A The illustration shows Comparative Example 4, where the heating rate of the burner is kept constant, and the dimensions (y-axis) of the product manufactured from the glass tube vary according to the product number (x-axis). For example... Figure 10A As shown, without any change in the heating rate of the burner to compensate for the temperature variation of the glass tube based on the product number, the average size of the product varied drastically in the first 10 to 15 products produced.

[0162] In Example 5, glass tubes are loaded into each retainer in a sequential order, and the heating rate of the burner is adjusted once for each revolution of the main turntable of the converter. Figure 10B The illustration shows how the dimensions (y-axis) of the product manufactured from the glass tube vary according to the product number (x-axis) for Example 5. In Example 5, the heating rate of the burner is adjusted based on the product number at the working end of the glass tube, on a per-revolution basis. Figure 10BAs shown, the heating rate of the burner in the heating station is adjusted based on the product number at the working end of the glass tube, on a per-revolution basis. This significantly reduces dimensional variations in products produced from the glass tube, especially in the first 10 to 15 products produced from each glass tube 102. Figure 10A and 10B As shown in the comparison, by adjusting the heating rate of the burners in the heating station based on the product number at the working end of the glass tube on a per-revolution basis, the dimensional variation of the produced products can be reduced by 80%. Therefore, changing the heating rate of one or more burners in one or more heating stations based on the product number at the working end of the glass tube can reduce the dimensional and appearance variations in the finished products.

[0163] Exhaust flow – Examples 6-9

[0164] For Examples 6-9, the effect of adjusting the exhaust flow rate near the heating station based on the article number at the working end of the glass tube on the dimensional changes of glass articles manufactured from the glass tube was investigated. The aluminosilicate glass tube was converted into a glass vial using the converter described in Comparative Example 1 above. For Example 6, the converter was operated without exhaust flow at the heating station. For each of Examples 7-9, the exhaust flow rate near the heating station was maintained constant throughout the entire process of the glass tube being consumed. Table 2 below provides the corresponding examples 6-9. Figure 12 The air flow rate and the attached diagram labels.

[0165] Table 2

[0166] Example Figure 12 Figure labels Exhaust flow rate (cfm) 6 1202 0 7 1204 1300 8 1206 2600 9 1208 3900

[0167] Figure 12 The illustration shows how the parameters (y-axis) of the dimensions of the indicator glass vials in Examples 6-9 vary according to the product number (x-axis). Figure 12 As shown, the exhaust flow rate near the heating station can affect the dimensional changes of the glass vials. Changing the exhaust flow rate near the heating station can also cause dimensional deviations. These effects can be used to manipulate the glass tube temperature at the working end during heating to compensate for the temperature changes in the glass tube during consumption as the converter rotates multiple times.

[0168] Although various embodiments of the converter 100 and the system and method for producing multiple articles from the glass tube 102 have been described herein, it should be understood that these embodiments and techniques can each be used alone or in combination with one or more embodiments and techniques.

[0169] It will be apparent to those skilled in the art that various modifications and variations can be made to the embodiments described herein without departing from the spirit and scope of the claimed subject matter. Therefore, this specification is intended to cover modifications and variations of the various embodiments described herein, provided that such modifications and variations fall within the scope of the appended claims and their equivalents.

Claims

1. A method for producing a plurality of articles from a glass tube, the method comprising: The working end of the glass tube is fixed in the glass tube holder of the converter, the converter having multiple processing stations, including at least one heating station and at least one forming station after the at least one heating station, wherein the converter moves the glass tube holder through the multiple processing stations, wherein the glass tube of initial length comprises multiple continuous segments, each of the multiple continuous segments corresponding to a product and having a product number; The working end of the glass tube is heated at at least one heating station; Based on the product number corresponding to the working end of the glass tube, the heating amount of the glass tube is increased or decreased. In this case, increasing or decreasing the heating amount based on the product number reduces the change in tube temperature and / or product size between one product number and the next product number. In the at least one forming station, at least one feature of the article is formed at the working end of the glass tube; At the separation station, the product is separated from the working end of the glass tube, and The glass tube is rotated downwards in the glass tube holder to form the subsequent article.

2. The method as described in claim 1, wherein, Increasing or decreasing the heating amount of the glass tube includes at least one of the following: Based on the product number at the working end of the glass tube, increase or decrease the burner dwell time when the working end of the glass tube contacts the heating element in the at least one heating station; Based on the product number at the working end of the glass tube, the heating rate of the heating element in at least one heating station is increased or decreased; or Based on the product number of the working end of the glass tube, adjust the negative pressure generated by the discharge system near the glass tube in the at least one heating station.

3. The method as described in claim 1, wherein, The plurality of processing stations include a plurality of heating stations, and the method includes: increasing or decreasing the heating amount of the glass tube in each of the plurality of heating stations based on the product number corresponding to the working end of the glass tube.

4. The method of claim 2, wherein, Increasing or decreasing the heating amount at the working end of the glass tube includes: increasing or decreasing the burner residence time of the glass tube in contact with the heating element in the at least one heating station, based on the product number at the working end of the glass tube.

5. The method of claim 4, wherein, The heating element in the at least one heating station includes a rotary burner that is pivoted to engage with or not engage with the working end of the glass tube. Increasing or decreasing the burner dwell time includes adjusting the time it takes for the rotary burner to pivot into or out of engagement with the working end of the glass tube.

6. The method of claim 2, wherein, Increasing or decreasing the heating amount at the working end of the glass tube includes: increasing or decreasing the heating rate of the heating element in the at least one heating station based on the product number of the working end of the glass tube.

7. The method of claim 6, wherein, The heating element includes a burner, and increasing or decreasing the heating rate includes increasing or decreasing the flow rate of one or more combustion gases supplied to the burner, wherein the combustion gases include fuel gas as well as oxygen and / or air.

8. The method of claim 7, wherein, Increasing or decreasing the heating rate includes proportionally increasing or decreasing the flow rate of all combustion gases reaching the burner.

9. The method of claim 2, wherein, Increasing or decreasing the heating amount at the working end of the glass tube includes adjusting the negative pressure generated by the discharge system near the at least one heating station based on the product number at the working end of the glass tube.

10. The method of claim 9, wherein, Adjusting the negative pressure generated by the exhaust system near the at least one heating station includes: increasing or decreasing the speed of an air processor fluidly connected to an inlet vent located near the at least one heating station; adjusting the position of a damper disposed between the air processor and the inlet vent; adjusting the position of the inlet vent of the exhaust system relative to a glass tube in the at least one heating station; or a combination thereof.

11. The method of claim 1, wherein the converter comprises a plurality of glass tube holders, and the method comprises: Each of the multiple glass tube holders is moved through each of the multiple processing stations; as well as Each time multiple glass tube holders move to the next processing station, the heating amount at the working end of the glass tube is increased or decreased based on the product number.

12. The method of claim 1, wherein, The converter includes multiple glass tube holders, and the method further includes securing new lengths of glass tubes in each of the multiple glass tube holders in a sequential order, starting with a first glass tube.

13. The method of claim 12, wherein, In response to a change in the product number at the working end of the first glass tube at the at least one heating station, the heating amount at the working end of the first glass tube is changed based on the product number, and the heating amount at the at least one heating station is maintained between glass tubes until the first glass tube returns to the at least one heating station and the product number at the working end of the first glass tube changes.

14. A system for producing multiple articles from a glass tube, the system comprising: A converter, comprising multiple processing stations including at least one heating station, at least one forming station, and a separating station, wherein the converter is operated to move a glass tube through the multiple processing stations; and A system controller communicatively connected to the converter, the system controller including a processor and a storage medium containing computer-readable and executable instructions, which, when executed by the processor, cause the system controller to perform the following: The product number at the working end of the glass tube is automatically determined, wherein the product number includes an integer corresponding to a continuous segment of the glass tube of the initial length, with each continuous segment corresponding to one product; and Based on the product number at the working end of the glass tube, the heating amount of the glass tube in the at least one heating station is increased or decreased.

15. The system of claim 14, wherein, The at least one heating station includes a rotary burner that is operable to pivot into and out of engagement with the working end of the glass tube, and a system controller is communicatively connected to the rotary burner.

16. The system of claim 15, wherein, When the processor executes computer-readable and executable instructions, the instructions cause the system controller to automatically increase or decrease the burner dwell time at the working end of the glass tube by pivoting the rotary burner to engage or disengage with the working end of the glass tube, based on the article number at the working end of the glass tube.

17. The system of claim 14, wherein, The at least one heating station includes at least one burner and at least one flow controller, which is operated to increase or decrease the mass flow rate of one or more combustion gases reaching the at least one burner.

18. The system of claim 17, wherein, When the processor executes computer-readable and executable instructions, the instructions cause the system controller to automatically increase or decrease the mass flow rate of one or more combustion gases reaching the at least one burner based on the article number at the working end of the glass tube.

19. The system of claim 14, wherein, The converter includes an exhaust system comprising at least one inlet vent and an air processor fluidly connected to the at least one inlet vent.

20. The system of claim 19, wherein, When the processor executes computer-readable and executable instructions, the instructions cause the system controller to automatically adjust the negative pressure generated by the discharge system near the glass tube based on the product number at the working end of the glass tube.

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