Distribution shift control method for converting glass tubes into glass articles

Abstract

A method for controlling a converter includes operating the converter to produce glass articles from a glass tube, the converter including a plurality of processing stations, and operating the converter includes sequentially translating the glass tube through the processing stations. The method includes measuring the attributes of the glass articles during or after conversion, developing an attribute distribution from the attribute measurements, and shifting the attribute distribution within a specified range of attributes. Shifting the attribute distribution within a specified range increases the yield of the glass articles. A system for converting glass articles from a glass tube includes a converter, a measuring device, a control device, and a control system operable to perform some or all of the methods disclosed herein for controlling the converter.

Description

Technical Field

[0001] Cross - reference to Related Applications This application claims the benefit of priority under 35 U.S.C. § 119 to U.S. Provisional Application No. 63 / 471,872, filed on June 8, 2023, the content of which is relied upon herein and incorporated by reference in its entirety.

[0002] Field This specification generally relates to systems and methods for producing glass articles from glass tubes, and more particularly, to systems and methods for controlling a glass tube conversion process for converting a glass tube into a glass vial.

Background Art

[0003] Historically, glass has been used as a preferred material for packaging pharmaceuticals due to its hermeticity, optical transparency, and superior chemical durability compared to other materials. Specifically, the glass used in pharmaceutical packaging must have appropriate chemical durability to prevent affecting the stability of the pharmaceutical compounds and / or pharmaceutical formulations contained therein. Suitable chemically durable glasses include, but are not limited to, those glass compositions within the ASTM standard "Type IA" and "Type IB" glass compositions that have demonstrated a record of chemical durability.

[0004] Glass tubing can be converted into various glass articles for use in pharmaceutical applications, including, but not limited to, vials, syringes, ampoules, cartridges, and other glass articles. Glass tubing can be converted, for example, in a "conversion machine." Conversion machines have been in use for over 75 years and are now manufactured by various commercial and internal equipment suppliers. These conversion machines typically reshape long lengths of glass tubing into multiple glass articles using steps that include flame processing, rotary and stationary tool shaping, thermal separation, or etching and impact cutting steps, as well as other steps. Various burners and shaping tools are often used to shape one or more glass articles from the glass tubing and to separate each of the glass articles from the glass tubing. [Overview of the project]

[0005] While a glass tube is converted into a glass article using a conversion machine (i.e., a converter), a heating element such as a burner heats the glass of the glass tube to a temperature at which the viscosity of the glass allows it to form into one or more feature parts of the glass article. A forming station includes forming tools such as pin and wheel assemblies that come into contact with the heated glass tube and form the internal and external dimensions of the feature parts of the finished glass article. The converter may have hundreds of process settings and inputs that can affect the dimensional yield and defect rate achieved by the conversion machine.

[0006] Current methods for producing glass articles from glass tubes using conversion machines have long relied on manual observation of the behavior of one or more attributes of the glass article, followed by manual adjustment of one or more process variables, or, if the actuator is a servo driven by a dial-adjustable stage or programmable logic controller. The conversion process is usually a gradual drift, but can be interrupted by sudden shifts in one or more attributes of the glass article. Therefore, the maximum achievable yield from a conversion machine can fluctuate over time and may depend on the evolution of the shape of the distribution of one or more attributes of the glass article over time. Furthermore, attributes exhibiting a non-normal distribution in their attribute measurements (e.g., asymmetric, multimodal, or similar) may be difficult to control to maximize yield through human operators or automated feedback control methods.

[0007] Therefore, in order to increase the yield of glass articles from glass tubes, there is a need for a system and method to control one or more operations of a converter that converts glass tubes into glass articles such as pharmaceutical packaging.

[0008] A first aspect of the present disclosure may relate to a method for controlling a converter for producing glass articles from glass tubes. The method may include operating the converter to produce the glass articles from the glass tubes, the converter may comprise a plurality of processing stations, and operating the converter may include sequentially translating the glass tubes through each of the plurality of processing stations. The method may include measuring the attributes of the glass articles during or after the conversion, wherein the attributes undergo gradual changes over time, sudden changes, or both, measuring, developing an attribute distribution from the measured values ​​of the attributes, and shifting the attribute distribution within a specified range of the attributes, the shifting of the attribute distribution may increase the yield of the glass articles.

[0009] A second aspect of this disclosure may include the first aspect, and shifting the attribute distribution may include adjusting at least one process setting.

[0010] A third aspect of the present disclosure, May, a second aspect, may include adjusting the at least one process setting by determining an updated setpoint of the at least one process setting and adjusting the at least one process setting to the updated setpoint.

[0011] A fourth aspect of the present disclosure may include a third aspect, in which determining the updated setpoint of the at least one process setting may include determining a shift in the attribute distribution within the specification range that increases the yield of the glass article, and calculating the updated setpoint of the at least one process setting from the magnitude and direction of the shift in the attribute distribution and the control relationship between the at least one process setting and the attributes.

[0012] A fifth aspect of the present disclosure may include a fourth aspect, which may include determining the shift in the attribute distribution within the specification range that increases the yield of the glass article by performing a plurality of simulations, in each of the plurality of simulations, the attribute distribution may be shifted by different magnitudes, directions, or both; determining the best simulation from the plurality of simulations, the best simulation which can produce the maximum yield of the glass article; and setting the magnitude and direction of the shift in the attribute distribution to be equal to the magnitude and direction corresponding to the best simulation.

[0013] A sixth aspect of the present disclosure may include a fifth aspect, wherein two or more of the simulations may result in a 100% yield of the glass articles, and the best simulation may include a simulation in which the minimum absolute value of the difference between the measured value of the attribute distribution and the upper or lower limit of the specification range is the maximum, and the yield of the glass articles is 100%.

[0014] A seventh aspect of the present disclosure may include either the fifth or sixth aspect, wherein two or more of a plurality of simulations may result in a 100% yield of the glass articles, the attribute may be known to drift toward the upper or lower limit of the specification range, the best simulation may include a simulation that results in a 100% yield of the glass articles, and provides the maximum absolute difference between either the upper or lower limit and the measurement closest to the upper or lower limit, respectively.

[0015] An eighth aspect of the present disclosure may include any one of the fifth to seventh aspects, wherein determining the shift in the attribute distribution within the specification range may include determining whether the benefit of shifting the attribute distribution within the specification range is greater than the cost of shifting the attribute distribution; adjusting the at least one process setting to shift the attribute distribution within the specification range if the benefit of shifting the attribute distribution is greater than the cost; and maintaining the at least one process setting if the benefit of shifting the attribute distribution is less than the cost.

[0016] A ninth aspect of the present disclosure may include any one of the fourth to eighth aspects, wherein determining the shift in the attribute distribution within the specification range that increases the yield of the glass article may include analyzing the attribute distribution to determine the characteristics, relationships, or both that are features of the attribute distribution, and calculating the shift in the attribute distribution within the specification range that increases the yield of the glass article from the characteristics, relationships, or both that are features of the attribute distribution.

[0017] A tenth aspect of the present disclosure may include any one of the first to second aspects, 10. The method of claim 9, wherein analyzing the attribute distribution and determining the characteristics, relationships, or both that characterize the attribute distribution includes applying a first principle, a statistical method, or both to the attribute distribution.

[0018] An eleventh aspect of the present disclosure may include any one of the fourth to tenth aspects, which further includes: measuring the attributes of the glass article after adjusting the at least one process setting; developing a shifted attribute distribution based on the measured attributes of the glass article after adjusting the at least one process setting; comparing the shifted attribute distribution with a predicted attribute distribution, the predicted attribute distribution may be calculated by applying the shift to the attribute distribution that occurred before adjusting the at least one process setting; and further adjusting the at least one process setting based on the comparison between the shifted attribute distribution and the predicted attribute distribution.

[0019] A twelfth aspect of the present disclosure may include an eleventh aspect, wherein comparing the shifted attribute distribution with the predicted attribute distribution may include calculating an error between the same characteristics of the shifted attribute distribution and the same characteristics of the predicted attribute distribution, and shifting the shifted attribute distribution may be based on the error.

[0020] A thirteenth aspect of the present disclosure may include either one of the eleventh aspects of the twelfth aspect, which includes developing an updated control relationship between at least one process setting and an attribute.

[0021] A fourteenth aspect of this disclosure may include a thirteenth aspect, in which developing the updated control relationship may include designing an experimental process or calibration.

[0022] A 15th aspect of the present disclosure may include any one of the second to 14th aspects, wherein adjusting the at least one process setting may include determining one or more causes of the deviation of the attribute distribution outside the specification range, and modifying the adjustment of the at least one process setting to the setting point in accordance with the one or more causes of the deviation of the attribute distribution.

[0023] A sixteenth aspect of the present disclosure may include any one of the first to fifteenth aspects, wherein the converter may comprise a plurality of holders, and operating the converter may include fixing glass tubes to two or more of the plurality of holders, and sequentially translating each of the plurality of holders through the plurality of processing stations, the method may further include developing an attribute distribution for each of the plurality of holders from the measured values ​​of the attribute, and shifting the attribute distribution for each of the plurality of holders within the specification range of the attribute, wherein shifting the attribute distribution for each of the plurality of holders may increase the yield of the glass articles.

[0024] A 17th aspect of the present disclosure may include any one of the 1st to 16th aspects, wherein shifting the attribute distribution within the specification range may include determining whether the shift in the attribute distribution within the specification range of the attribute increases the yield of the glass article, and if the shift in the attribute distribution increases the yield of the glass article, shifting the attribute distribution within the specification range for the attribute.

[0025] The 18th aspect of the present disclosure may include any one of the 1st to 17th aspects. When the shift in the attribute distribution does not increase the yield, the method may include maintaining the at least one process setting at the current set point.

[0026] The 19th aspect of the present disclosure may include any one of the 1st to 18th aspects. The glass article may be a glass vial, and the attributes may be selected from the vial height, the inner diameter of the flange, the outer diameter of the flange, the thickness of the flange, the height of the flange, the radius of the shoulder, the height of the shoulder, the outer diameter of the neck, or a combination thereof.

[0027] The 20th aspect of the present disclosure may include the 19th aspect. The attribute may be the vial height of the glass vial.

[0028] The 21st aspect of the present disclosure may include the 20th aspect. The at least one process setting may be the stopper height in the tube drop station of the converter.

[0029] The 22nd aspect of the present disclosure may include the 19th aspect. The glass article may be a glass vial, and the attribute may be the inner diameter of the flange of the glass vial.

[0030] The 23rd aspect of the present disclosure may include any one of the 1st to 22nd aspects. Developing the attribute distribution may include measuring the attribute over a lookback window.

[0031] The 24th aspect of the present disclosure may include the 23rd aspect. The lookback window may include a statistically relevant number of produced glass articles.

[0032] The 25th aspect of the present disclosure may include any one of the 1st to 24th aspects. The aspect may further include measuring the attribute of the glass article after forming one or more features of the glass article at the processed end of the glass tube.

[0033] A 26th aspect of the present disclosure may include any one of the first to 25 aspects, wherein operating the converter may include forming one or more feature portions of the glass article at the processed end of the glass tube, separating the glass article from the processed end of the glass tube after forming, and measuring the attributes after forming the one or more feature portions of the glass article and separating the glass article from the processed end of the glass tube.

[0034] A 27th aspect of the present disclosure may include any one of the first to 26th aspects, which includes measuring the attributes of the glass article after conversion for production of the glass article.

[0035] A 29th aspect of the present disclosure may include a 27th aspect, which further includes operating the converter to produce the glass article from the glass tube, and then annealing the glass article, wherein the measurement of the attributes may be performed after the glass article has been annealed.

[0036] A 29th aspect of this disclosure may include any one of the first to 28th aspects, wherein the attribute distribution may deviate from a normal distribution or may be an asymmetric distribution.

[0037] A thirtieth aspect of the present disclosure may relate to a system for producing glass articles from glass tubes, the system may include a converter comprising a plurality of processing stations and at least one control device, the converter may be operable to sequentially translate the glass tube through each of the processing stations, the sequential translation of the glass tube through each of the processing stations may form one or more feature portions of the glass article, the glass article may be separated from the processed end of the glass tube, the glass article may include attributes, and the at least one control device may be operable to change process settings affecting the attributes of the glass article. The system may also include a measuring device positioned to measure the attributes of the glass article during or after the conversion, and a control system communicatively coupled to the converter and the measuring device. The control system may include a processor, a memory module communicatively coupled to the processor, and machine-readable and executable instructions stored in the memory module. When the machine-readable and executable instructions are executed by the processor, the control system will automatically measure the attributes of the glass article using the measuring device, develop an attribute distribution based on the measured values ​​of the attributes of the glass article, determine whether a shift in the attribute distribution within the specified range of the attributes increases the yield of the glass article, and if the shift in the attribute distribution increases the yield of the glass article, the attribute distribution may be shifted within the specified range of the attributes.

[0038] A 31st aspect of the present disclosure may include a 30th aspect, wherein the measuring device may be positioned within the processing station of the converter, coupled to one or more holders of the converter, positioned downstream of the converter, or a combination thereof.

[0039] A 32nd aspect of the present disclosure may include either a 30th or a 31st aspect, wherein the system may include an annealing process for annealing the glass article, and the measuring device may be positioned downstream of the annealing process.

[0040] A 33rd aspect of the present disclosure may include any one of the 30th to 32nd aspects, wherein the plurality of processing stations may comprise a tube length drop station comprising a mechanical stopper and a stopper actuator, the stopper actuator may be configured to change the position of the mechanical stopper axially with respect to the processed end of the glass tube, and the attribute may be the overall height of the glass article.

[0041] A 34th aspect of the present disclosure may include any one of the 30th to 33rd aspects, wherein the glass article may be a glass vial, and the plurality of processing stations may include one or more forming tools and one or more forming tool actuators operable to change the position of one or more forming tools, and comprising at least one flange forming station, wherein the attribute may be the inner diameter of the flange of the glass vial.

[0042] A 35th aspect of the present disclosure may include any one of the 30th to 34th aspects, wherein the machine-readable and executable instructions may cause the control system to automatically adjust at least one process setting of the converter to shift the attribute distribution within the specified range for the attribute when executed by the processor.

[0043] A 36th aspect of the present disclosure may include a 35th aspect, wherein the machine-readable and executable instructions, when executed by the processor, cause the control system to automatically determine an updated setpoint for the at least one process setting if the shift in the attribute distribution increases the yield of the glass articles, and to adjust the at least one process setting to the updated setpoint.

[0044] A 37th aspect of the present disclosure may include a 36th aspect, wherein the machine-readable and executable instructions, when executed by the processor, cause the control system to automatically calculate the updated setpoint of the at least one process setting from the magnitude and direction of the shift in the attribute distribution, and the control relationship between the at least one process setting and the attribute.

[0045] A 38th aspect of the present disclosure may include a 37th aspect, wherein the machine-readable and executable instructions, when executed by the processor, can cause the control system to automatically perform a plurality of simulations, in each of the plurality of simulations, the attribute distribution may be shifted by different magnitudes, directions, or both; determine the best simulation from the plurality of simulations, the best simulation which can produce the maximum yield of the glass article; and set the magnitude and direction of the shift in the attribute distribution to be equal to the magnitude and direction corresponding to the best simulation.

[0046] It should be understood that the above overview and the following detailed description are intended to illustrate various embodiments and provide an overview or framework for understanding the nature and characteristics of the claimed subject matter. The accompanying drawings are included to provide a further understanding of the various embodiments and are incorporated herein and constitute part of this specification. The drawings illustrate the various embodiments described herein and, together with the descriptions, help to illustrate the principles and operation of the claimed subject matter. [Brief explanation of the drawing]

[0047] [Figure 1] A schematic front view is provided for an embodiment of a system comprising a converter for producing glass articles from glass tubes, according to one or more embodiments shown and described herein. [Figure 2]Figure 1 schematically illustrates the top views of the main and secondary turrets of the converter according to one or more embodiments shown and described herein. [Figure 3] Figures 1 and 2 schematically illustrate the heating stations of the converters according to one or more embodiments shown and described herein. [Figure 4] A schematic illustration of one embodiment of the molding station of the converter shown in Figure 1, according to one or more embodiments shown and described herein, is provided. [Figure 5] Another embodiment of the molding station of the converter shown in Figure 1, according to one or more embodiments shown and described herein, is schematically depicted. [Figure 6] Figure 1 schematically illustrates the tube length drop station of the converter according to one or more embodiments shown and described herein. [Figure 7] Figure 1 schematically illustrates the isolation station of the converter according to one or more embodiments shown and described herein. [Figure 8] Figure 1 schematically illustrates the measurement station of the converter according to one or more embodiments shown and described herein. [Figure 9] A schematic perspective view of the section of the glass tube before conversion in the converter of Figure 1, according to one or more embodiments shown and described herein, is provided. [Figure 10] A schematic cross-sectional view of a glass article containing a vial, according to one or more embodiments shown and described herein, is provided. [Figure 11] This specification schematically describes another embodiment of a system comprising a converter for converting glass articles to be produced from glass tubes, and a distributed computing environment communicatively coupled to the converter, according to one or more embodiments shown and described herein. [Figure 12] This is a flowchart of a method for controlling the operation of the converters in Figures 1 and 11, according to one or more embodiments shown and described herein. [Figure 13]For glass vials produced according to one or more embodiments shown and described herein, the relative vial height (y-axis) of the glass vial is plotted as a function of time (x-axis). [Figure 14] For glass vials produced by the system of Figure 1 according to one or more embodiments shown and described herein, the relative flange inner diameter (y-axis) is plotted as a function of time (x-axis). [Figure 15] For the glass vial shown in Figure 14 according to one or more embodiments described herein, the box plot of the relative flange inner diameter (y-axis) is graphically plotted as a function of the number of holders (x-axis). [Figure 16] For the glass vial shown in Figure 14 according to one or more embodiments described herein, the yield (y-axis) with respect to the flange inner diameter is plotted graphically as a function of the number of holders (x-axis). [Figure 17] For the glass vial of Figure 14 according to one or more embodiments shown and described herein, the actual hysteretic yield and predicted yield with respect to the flange inner diameter (y-axis) are graphically plotted as a function of time (x-axis). [Figure 18] For the glass vial shown in Figure 14 according to one or more embodiments described herein, a graph illustrates the history of recommended changes in process settings (y-axis) based on the shift in attribute distribution as a function of time (x-axis). [Figure 19] The yield of glass vials against the flange inner diameter for a series of production trials for producing glass vials according to one or more embodiments shown and described herein is graphically illustrated. [Modes for carrying out the invention]

[0048] Embodiments of the systems and methods of the present disclosure for controlling the operation of a glass tube conversion process for producing glass articles are referred to in detail here, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numerals are used throughout the drawings to refer to the same or similar parts. Referring here to Figure 1, the system 400 disclosed herein for producing a glass article 103 from a glass tube 102 comprises a converter 100, a measuring device 360 ​​positioned to measure the attributes of the glass article 103 during or after conversion, and a control system 402 communicatively coupled to the converter 100 and the measuring device 360. The converter 100 may include a plurality of processing stations 106 and at least one control device, and the converter 100 may be operable to continuously translate the glass tube 102 through each of the processing stations 106. Continuously translating the glass tube through each of the processing stations 106 shapes one or more feature portions of the glass article 103 and separates the glass article 103 from the processed end of the glass tube 102. The glass article 103 includes at least one attribute. At least one control device may be operable to change the process settings of the converter 100 that affect the attribute of the glass article 103. The control system 402 may include a processor, a memory module communicatively coupled to the processor, and machine-readable and executable instructions stored in the memory module. When executed by the processor, the machine-readable and executable instructions may cause the control system to automatically measure the attribute of the glass article 103 using a measuring device 360, develop an attribute distribution based on the measured values ​​of the attribute of the glass article 103, determine whether a shift in the attribute distribution within the attribute specification range increases the yield of the glass article 103, and, if the shift in the attribute distribution increases the yield of the glass article 103, shift the attribute distribution within the attribute specification range.

[0049] A method disclosed herein for controlling a converter 100 for producing glass articles 103 from a glass tube 102 may include operating the converter 100 to produce glass articles 103 from the glass tube 102, wherein the converter 100 comprises a plurality of processing stations 106, and operating the converter 100 includes sequentially translating the glass tube 102 through each of the plurality of processing stations 106. The method may further include measuring the attributes of the glass articles 103 during or after conversion, wherein the attributes undergo gradual changes over time, sudden changes (e.g., stepwise changes), or both. The method may further include developing an attribute distribution from the measured attributes and shifting the attribute distribution within a specified range of attributes, wherein shifting the attribute distribution can increase the yield of the glass articles 103. The systems and methods herein may enable control of the attributes of glass articles having asymmetric, multimodal, or other nonnormal attribute distributions.

[0050] The directional terms used herein, such as up, down, right, left, front, back, top, and bottom, are used only in reference to the depicted figures and the coordinate axes provided therewith, and are not intended to imply absolute orientation.

[0051] Unless otherwise specified, no method described herein is to be interpreted as requiring its steps to be performed in a specific order, nor is it intended that any apparatus be required to have a specific orientation. Therefore, if a method claim does not actually list the order in which its steps should be followed, or if any apparatus claim does not actually list an order or orientation for its individual components, or if it is not otherwise specifically stated in the claim or specification that the steps should be limited to a specific order, or if no specific order or orientation for the components of the apparatus is listed, no order or orientation is to be inferred in any sense. This includes all possible implicit grounds for interpretation, including logical matters relating to the arrangement of steps, the flow of operation, the order of components, or the orientation of components, the plain meaning derived from grammatical organization or punctuation, and the number or type of embodiments described herein.

[0052] As used herein, the singular forms “a,” “an,” and “the” include multiple referents unless explicitly indicated otherwise by the context. Therefore, for example, a reference to a “a” component includes embodiments having two or more such components unless explicitly indicated otherwise by the context.

[0053] As used herein, the “processed end” of the glass tube is the end of the glass tube oriented toward the processing station of the main turret of the converter relative to the holder, and the “unprocessed end” of the glass tube is the end of the glass tube oriented away from the processing station of the main turret.

[0054] As used herein, “residence time” of a converter refers to the duration that a glass tube spends in a particular processing station before passing through to the next subsequent processing station.

[0055] As used herein, the term “active time” refers to the duration of time during which a glass tube is maintained in engagement with at least one heating element or at least one forming tool while it is in a particular processing station.

[0056] As used herein, the term “indexing time,” when used in reference to an indexing converter, refers to the duration required to index a glass tube from one processing station to the next. “Dwell time,” “active time,” and “indexing time” are all measured in hours.

[0057] When used in relation to a heating station, "engagement" of a burner with a glass tube refers to positioning the burner so that the flame from the burner extends toward the glass tube or contacts the glass tube to heat it. Conversely, when a burner is disengaged from a glass tube, it is positioned so that the flame from the burner is directed away from the glass tube, or so that the flame is moved far enough away from the glass tube that it does not contact the glass tube or directly heat it.

[0058] When used in reference to molding tools within a molding station, the term "engagement" refers to the molding tool in contact with the glass tube. When the molding tool is disengaged from the glass tube, the molding tool does not come into contact with the glass tube.

[0059] As used herein, the term “partial rate” refers to the converter’s production rate or throughput rate in units of the number of glass articles per unit time.

[0060] As used herein, the term “circumference” of a glass tube refers to the set of points on the glass tube at a constant radius r from the central axis D of the glass tube, within 360 degrees from a specific Z position (i.e., a position on the + / -Z axis in the figure). The circumference of a glass tube may coincide, for example, with the outer surface of the glass tube at a specific Z position or the inner surface of the glass tube at a specific Z position.

[0061] As used herein, the term "operation" refers to the normal steady-state operation of the converter. Therefore, as used herein, "running settings" refers to the settings of the converter for the normal steady-state operation of the converter.

[0062] As used herein, the terms “upstream” and “downstream” refer to the positioning of the converter’s processing stations relative to each other. If the glass tube encounters a second processing station before encountering a first processing station, the first processing station is considered “downstream” of the second processing station. Similarly, if the glass tube encounters a first processing station before encountering a second processing station, the first processing station is considered “upstream” of the second processing station.

[0063] Glass tube material can be converted into glass articles, specifically, but not limited to, vials, vacuum containers, syringes, ampoules, cartridges, bottles, and other glass articles, for use in pharmaceutical applications. Glass tube material can be converted into these glass articles using a converter (i.e., a conversion machine) that includes multiple processing stations. Processing stations may, among other types of processing stations, include heating stations, forming stations, tube drop stations, thermal separation stations, and puncture stations. The conversion machine typically, but not limited to, uses steps including heating, rotation and stationary tool forming, separation (e.g., thermal separation or stencil and impact cutting steps), puncture, cooling, measurement, or other processing steps to reshape a long length of glass tube into multiple glass articles. Thus, the glass articles produced through the conversion process carried out on the conversion machine are subjected to a series of heating elements and forming tools to shape the glass tube into a specific shape and dimensions, and to separate the formed glass articles from the processed ends of the glass tube.

[0064] Referring to Figure 1, one embodiment of a system 400 for converting a glass tube 102 into a glass article 103 is schematically depicted. The system 400 may comprise a converter 100 for converting the glass tube 102 into the glass article 103, and a control system 402 communicatively coupled to the converter 100. The converter 100 may include a base 104 having a plurality of processing stations 106, and a main turret 108 positioned on the base 104 and rotatable about a central axis A relative to the base 104. The converter 100 may further include a glass tube loading turret 110 positioned on the main turret 108 for feeding the glass tube 102 to the main turret 108. The converter 100 may also include a plurality of secondary processing stations 112 on the base 104, and a secondary turret 114 which may be rotatable relative to the base 104.

[0065] As schematically illustrated in Figure 1, the base 104 of the converter 100 may be stationary, and processing stations 106 may be coupled to the base 104. Multiple processing stations 106 may be spaced apart from each other and arranged within a main circuit 116. In some embodiments, the main circuit 116 may be circular, so that a main turret 108 can index or continuously move the glass tube 102 through the multiple processing stations 106 by the rotation of the main turret 108 about a central axis A. Alternatively, in other embodiments, the main circuit 116 may be a linear arrangement of processing stations 106. Although described herein with reference to a circular layout of processing stations 106, it will be understood that the subject matter disclosed herein is equally applicable to converters having other arrangements of processing stations 106, such as linear, curved, or irregularly shaped arrangements of processing stations 106.

[0066] The type and / or shape of the glass articles produced from the glass tube 102 may affect the total number of processing stations 106 in the converter 100. The number of processing stations 106 in the main turret 108 can range from 14 to 32. 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 circuit 116, but it is understood that the converter 100 may have more or fewer processing stations 106 than 16 in the main circuit 116. The processing stations 106 may include, as an example and not limited to, one or more heating, molding, polishing, cooling, tube length drop, separation, drilling, measuring, feeding, discharge stations, other processing stations, or combinations thereof for producing glass articles from the glass tube 102. The type and / or shape of the articles produced from the glass tube 102 may also affect the type of processing stations 106 and / or the order of the processing stations 106 in the converter 100.

[0067] The main turret 108 may be positioned on the base 104 and may be rotatably coupled to the base 104 so that the main turret 108 can rotate relative to the base 104 about a central axis A. A drive motor (not shown) may be used to rotate the main turret 108 relative to the base 104. The main turret 108 may include a plurality of holders 130 configured to removably fix each glass tube 102 to the main turret 108. The holders 130 may be clamps, chucks, or other holding devices, or a combination of holding devices. In embodiments, the holders 130 may be chucks. The holders 130 may orient each glass tube 102 so that the glass tube 102 is parallel to the central axis A of the main turret 108. The converter 100 is described herein in the context of a vertically oriented converter 100, but it should be understood that the converter 100 may be oriented horizontally or at an angle so that the glass tube 102 is non-vertical during processing. Each holder 130 can be oriented to position the glass tube 102 within each of the successive processing stations 106 of the main circuit 116 as the main turret 108 continuously translates the holder 130 and the glass tube 102 through each of the processing stations 106.

[0068] In an embodiment, the converter 100 may be capable of gradually translating each of the multiple holders 130 through a plurality of processing stations 106. In an embodiment, the converter 100 may index the holders 130 through each of the processing stations 106. Indexing may refer to a stepwise process of moving the glass tube 102 into a processing station 106, maintaining the glass tube 102 at a stationary XYZ position within the processing station 106 for a certain residence time, and then indexing the glass tube 102 to the next processing station 106. Alternatively, in an embodiment, the converter 100 may be capable of continuously translating the plurality of holders 130 through the conversion process. In an embodiment, the processing station 106 may translate with the glass tube 102 during the glass tube 102's active time at the processing station.

[0069] Each holder 130 is individually rotatable relative to the main turret 108, allowing the glass tube 102 to rotate around its central axis D, which can be parallel to the central axis A of the main turret 108. The rotation of the holders 130 allows the glass tube 102 to rotate around its central axis D relative to a stationary burner, molding tool, cooling nozzle, or other feature of the processing station 106. The heating element or molding tool within the processing station 106 can be maintained in a fixed position relative to the glass tube 102, and the rotation of the glass tube 102 around the central axis D can allow the entire circumference of the glass tube 102 to be exposed to the heating element or molding tool.

[0070] Referring to Figures 1 and 2, the converter 100 may include a plurality of secondary processing stations 112, which may also be spaced apart and located within a secondary circuit 118 (Figure 2). The converter 100 may include a secondary turret 114 (Figure 1) for indexing or continuously moving glass articles separated from the glass tube 102 through the plurality of secondary processing stations 112. The secondary turret 114 may rotate about axis B in the opposite direction 224 to the main turret 108. In embodiments, the secondary turret 114 may rotate in the same direction as the main turret 108. The secondary turret 114 may also include a plurality of secondary holders 132 for holding the glass articles 103 and positioning the glass articles 103 to engage continuously with each of the secondary processing stations 112. The secondary turret 114 receives the glass article 103 from the separation station 206 (Figure 2) of the main turret 108 and, through the rotation of the secondary turret 114, indexes or continuously moves the article 103 through a plurality of secondary processing stations 112, and the finished glass article can be discharged from the converter 100. Although shown in a circular pattern, it is understood that the secondary processing stations 112 may be arranged in a linear, curved, or irregular configuration. The secondary processing stations 112 may be referred to as bottom forming machines. In the case of a glass article 103 that is a vial, the secondary processing station 112 may be capable of operating to form the bottom of the vial.

[0071] Referring now to Figure 2, as previously described, the multiple processing stations 106 of the converter 100 may include one or more heating stations 202, molding stations 204, separation stations 206, cooling stations 210, drilling stations 212, tube loading stations 214, discharge stations 216, measuring stations 218, tube length drop stations 220, other stations, and / or combinations thereof. Figure 2 schematically illustrates the arrangement of the processing stations 106 of the converter 100, which has a main circuit 116 of 16 processing stations 106 and a secondary circuit 118 of 8 secondary processing stations 112.

[0072] The main circuit 116 of the converter schematically depicted in Figure 2 may include one or more heating stations 202, a separation station 206, a drilling station 212, one or more forming stations 204, one or more cooling stations 210, a measuring station 218, a tube length drop station 220, and a tube loading station 214. Figure 2 depicts the main circuit 116 having a circular arrangement of processing stations 106, but as previously discussed, the main circuit 116 may have processing stations 106 positioned in other non-circular arrangements such as linear, curved, irregular, or other arrangements. The processing stations 106 in the main circuit 116 may be operable to form one or more feature portions of a glass article 103 on the processed end of a glass tube 102 and to separate the partially formed glass article 103 from the processed end of the glass tube 102.

[0073] The secondary processing stations of the secondary circuit may include one or more heating stations 202, molding stations 204, polishing stations 208, cooling stations 210, discharge stations 216, or other stations, or combinations of secondary processing stations 112. Figure 2 illustrates a secondary circuit having a circular arrangement of secondary processing stations 112, but as previously discussed, the secondary circuit may have secondary processing stations 112 positioned in other non-circular arrangements such as linear, curved, irregular shapes, or other arrangements. In embodiments, the secondary processing stations 112 of the secondary circuit 118 may be used to mold one or more feature parts of a glass article 103, such as a vial, ampoule, cartridge, or syringe, at the end of the glass article 103 opposite to the end molded by the main turret 108, for example. For example, in embodiments, the glass article 103 may be a vial, and the molding station 204 of the secondary circuit 118 may mold the bottom of the vial. Other feature parts such as ampoules, cartridges, and syringes are also conceivable. The secondary circuit 118 may include one or more polishing stations 208 for finishing the surface of the glass articles. The secondary circuit 118 may further include a plurality of cooling stations 210 and an discharge station 216, at which the finished glass articles 103 can be discharged from the converter 100. In embodiments, the secondary circuit 118 may include a measuring station 218.

[0074] Referring again to Figure 2, with respect to the translational direction 222 of the main turret 108, the heating station 202 may be positioned before the forming station 204 and before each of the separation stations 206 to preheat a target area of ​​the glass tube 102 to a viscosity to which the glass can be deformed and effectively shaped or stretched and separated. Referring now to Figure 3, one embodiment of the heating station 202 of the converter 100 is schematically depicted. Each of the heating stations 202 may include one or more heating elements 301. As illustrated in Figure 3, in an embodiment, the heating element 301 may include one or more burners 302, which are used to heat a target area of ​​the glass tube 102 before a forming operation performed at the forming station 204 (Figure 2) or a separation operation performed at the separation station 206 (Figure 2). Although Figure 3 depicts a single burner 302, it should be understood that multiple burners 302 may be employed within a single heating station 202. Each burner 302 may be fluidly coupled to a fuel gas source 304, an oxygen source 306, and optionally an air source 308. Examples of fuel gases for the burners 302 may include, but are not limited to, hydrogen, hydrocarbon fuel gases such as methane, propane, and butane, other fuel gases, or combinations thereof.

[0075] Each burner 302 may include a fuel control valve 310 for controlling the flow rate of fuel gas to the burner 302. Each burner 302 may also include an oxygen control valve 312 for controlling the mass flow rate of oxygen to the burner 302. Each burner 302 may further include an air control valve 314 for optionally controlling the flow rate of air to the burner 302. The burner 302 burns the fuel gas in the presence of an oxygen-containing gas and / or air to produce a flame that heats at least 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 burners, it is understood that the glass tube 102 may be heated using other heating elements or methods other than burners. Other heating elements may include, for example, a CO2 laser, but are not limited to, induction heaters, other heating devices, or a combination thereof.

[0076] The heating station 202 may further include a heating element positioning device 318 coupled to the burner 302. The heating element positioning device 318 may be operable to position the burner 302 relative to the glass tube 102 in the heating station 202 in a vertical direction (e.g., in the + / -Z direction of the coordinate axes in Figure 3), a horizontal direction (e.g., in the XY plane identified by the coordinate axes in Figure 3), or a combination of these directions. In embodiments, each heating element positioning device 318 may include one or more servo motors operable to automatically and / or incrementally adjust the position of the burner 302 in one or more directions. Any other type of positioning device that is or will be commercially available may be used with the heating element positioning device 318. A heating element positioning device 318, a fuel control valve 310, an oxygen control valve 312, an air control valve 314, or a combination thereof, may be communicatively coupled to the control system 402 to enable the control system 402 to control the vertical position, horizontal position, heat output, or a combination thereof of the heating element 301.

[0077] Referring again to Figure 2, the forming station 204 of the main turret 108 may be located downstream of the drilling station 212 and one or more heating stations 202 in the translational direction 222. One or more forming stations 204 may iteratively shape the glass tube 102 to form one or more features of the finished glass article. The forming station 204 of the main turret 108 may shape the processed end 150 (Figure 4) of the glass tube 102 heated in the upstream heating station 202 to form a feature on one end of the glass article 103, and the forming station 204 of the secondary turret 114 may shape the other end of the glass article 103 after the glass article 103 has been separated from the glass tube 102. In the embodiment, the converter 100 may be used to produce a glass article 103 which is a vial, and may include a forming station 204 of the main circuit 116, one or more shoulder forming stations, a flange forming station, a flange finishing station, or a combination thereof, with one or more heating stations 202 positioned in front of each of the forming stations 204.

[0078] The forming station 204 of the main turret 108 can form a feature at the first end of the glass article 103. Referring again to Figure 2, once the glass article 103 is separated from the glass tube 102 at the separation station 206, the glass article 103 can be moved to the secondary processing station 112 of the secondary turret 114. The secondary processing station 112 may include one or more forming stations 204 for forming the second end of the glass article 103, opposite to the first end. For example, the forming station 204 of the secondary processing station 112 can form one or more feature at the bottom (second end) of the glass article 103.

[0079] Referring here to Figures 4 and 5, an example of a forming station 204 of the converter 100 is schematically depicted. Each forming station 204 may include one or more forming tools 324 that may be rotatable about the tool axis E relative to the base 104 (Figure 1). As it passes through the forming station 204, the glass tube 102, heated in the previous heating station 202, is rotated by the holder 130. The forming tool 324 may engage with the glass tube 102 as the glass tube 102 rotates. Once engaged, the contact between the forming tool 324 and the heated glass tube 102 can form the glass tube 102 into a desired shape. The forming tool 324 may remain in contact with the glass tube 102 for the duration of the forming tool 324's active time. At the end of the active time, the forming tool actuator 326 may disengage the forming tool 324 from its engagement with the glass tube 102. Figure 4 schematically illustrates an embodiment of a forming station 204 for forming the shoulder 142 of a glass vial. Figure 5 schematically illustrates an exemplary embodiment of a forming station 204' for forming the flange 144 of a glass vial. The forming station 204' for forming the flange 144 may comprise three forming tools 324a, 324b, and 324c. Other types of forming tools 324 may be employed within the forming station 204 depending on the desired feature of the glass article 103.

[0080] Referring again to Figure 4, the molding tool actuator 326 may be operable to move the molding tool 324 to engage with and disengage from the glass tube 102. Moving the molding tool 324 to engage with and disengage from the glass tube 102 can control the timing of contact between the molding tool 324 and the glass tube 102. The timing of contact between the molding tool 324 and the glass tube 102 refers to the timing at which each of the molding tools 324 in the molding station 204 engages with and disengages from the glass tube 102. Adjusting the contact timing of the molding tool 324 can adjust the total contact time of each of the molding tools 324 that are in contact with the glass tube 102. The contact time refers to the duration for which the molding tool 324 is engaged with or in contact with the glass tube 102.

[0081] The molding tool actuator 326 may be further operable to change the position of the molding tool 324 relative to the glass tube 102 in the molding station 204 in the axial direction (i.e., in the + / -Z direction of the coordinate axes in Figure 3), the lateral direction (i.e., horizontally, or in the XY plane identified by the coordinate axes in Figure 4), or a combination of these directions. The molding position of the molding tool 324 refers to the position of the molding tool when the molding tool 324 engages with the glass tube 102. In embodiments, each molding tool actuator 326 may include one or more servo motors operable to automatically and / or incrementally adjust the position of the molding tool 324 in one or more directions of the coordinate axes in Figure 4. Any other type of positioning device that is or will be commercially available may be used as at least part of the molding tool actuator 326. The molding tool actuator 326 may be communicatively coupled to a control system 402, which may allow the control system 402 to change the axial position, lateral position, or both of the molding tool 324 when it is in the molding position. The axial (i.e., + / -Z direction) and / or lateral (i.e., position in the XY plane) position of the forming tool 324 relative to the glass tube 102 refers to the position of the forming tool 324 when it is engaged with the glass tube 102.

[0082] Referring here to Figure 5, another embodiment of the forming station 204 for forming the flange 144 of a glass article 103, which is a glass vial, is schematically depicted. The forming station 204 may include forming tools 324a and 324b, which may be outer forming tools. Each of the forming tools 324a and 324b may be operably coupled to outer forming tool actuators 326a and 326b. The forming station 204 may include an inner forming tool 324c. The inner forming tool 324c may be operably coupled to an inner forming tool actuator 328, which may be operable to actuate the inner forming tool 324c axially into the opening of the processed end 150 of the glass tube 102. The internal forming tool actuator 328 may be further operable to correct the axial position (i.e., the position in the + / -Z direction in Figure 5), the horizontal position (i.e., the position in the XY plane of the coordinate axes in Figure 5), or the position of both the internal forming tool 324c and the internal forming tool 324c when the internal forming tool 324c is actuated to engage with the glass tube 102 (i.e., actuated in the +Z direction towards the opening of the processed end of the glass tube).

[0083] Referring again to Figure 2, the tube length drop station 220 may be positioned behind the forming station 204 of the main circuit 116, between the forming station 204 and the separation station 206. Referring to Figure 6, the tube length drop station 220 may be operable to drop the glass tube 102, which has a partially formed glass article at the processed end 150, downward (i.e., in the -Z direction of the coordinate axes in Figure 6), thereby positioning the glass tube 102 for separation of the glass article 103 at the separation station 206. The tube length drop station 220 may determine the overall height attribute of the finished glass article 103.

[0084] Referring here to Figure 6, one embodiment of the tube length drop station 220 is schematically depicted. The tube length drop station 220 may include a mechanical stopper 330 positioned axially spaced in the -Z direction of the coordinate axes in Figure 6. The mechanical stopper 330 may be coupled to a stopper positioning device 332, which may be operable to change the position of the mechanical stopper 330 in the axial direction (+ / -Z direction of the coordinate axes in Figure 6) relative to the glass tube 102. The mechanical stopper 330 may be positioned axially (i.e., in the -Z direction of the coordinate axes in Figure 6) by a distance G from the processed end 150 of the glass tube 102. The distance G may be selected to produce the desired final overall height of the glass article 130. In an embodiment, the holder 130 may be a chuck 334 having a gripper 336 operable to grip the glass tube 102 so that the glass tube 102 can be maintained at an appropriate height and rotated during conversion. The chuck 334 may be communicatively coupled to a control system 402, which may be operable to actuate the gripper 336 of the chuck 334.

[0085] During the operation of the tube length drop station 220, the control system 402 may loosen the gripper 336 of the chuck 334. Loosening the gripper 336 of the chuck 334 may allow the glass tube 102 to slide or drop axially (i.e., in the -Z direction of the coordinate axes in Figure 6) until the glass tube 102 contacts the mechanical stopper 330. Thus, in the tube length drop station 220, the glass tube 102 is dropped from a first axial position to a second axial position with respect to the stationary axial position of the holder 130. After the glass tube 102 has dropped and stopped at the mechanical stopper 330, the control system 402 may re-engage the gripper 336 of the chuck 334 to fix the glass tube 102 to the second position. If the converter 100 is oriented vertically, gravity may be sufficient to drop the glass tube 102 to the second position. If the converter 100 is oriented horizontally, the converter 100 may include a separate glass tube actuator capable of moving the glass tube axially to a second position relative to the holder 130. In embodiments, instead of having a separate and dedicated tube length drop station 220 for the converter 100, the tube length drop function may be incorporated into the final forming station 204 upstream of the separation station 206. At the final forming station 204, the glass tube 102 can be dropped to a suitable height for separation immediately after the end of the final flange forming station and before translating the holder 130 and the glass tube 102 into the next processing station 106. Although described herein in the context of a separate tube length drop station 220, in embodiments, a mechanical stopper 330 and a stopper positioning device 332 may be incorporated into the final forming station 204 before separation, so that the tube drop function can be accomplished immediately after the end of the final forming operation and before translating the glass tube 102 into the next downstream processing station.

[0086] Referring again to Figure 2, the separation station 206 may be located downstream of the last forming station 204 in the translational direction 222 of the main turret 108. One or more heating stations 202 may be located upstream of the separation station 206, between the last forming station 204 and the separation station 206. At the separation station 206, the formed glass article 103 (Figure 1) can be separated from the glass tube 102 (Figure 1). The separation station 206 may also be a processing station 106, where, once the partially formed glass article 103 has been separated, it is transferred to a secondary turret 114 (Figure 1) for processing in a secondary processing station 112.

[0087] Referring here to Figure 7, one embodiment of the separation station 206 of the converter 100 is schematically depicted. The separation station 206 depicted in Figure 7 is a thermal separation station and may be positioned behind one or more heating stations 202 in the translational direction 222 of the main turret 108. Heating stations 202 positioned in front of the separation station 206 may heat the glass tube 102 to make the glass viscous. The separation station 206 may include a separation burner 348. The separation burner 348 may have any of the features previously described for the burner 302, including, but not limited to, a fuel gas control valve 310, an oxygen control valve 312, and / or an air control valve 314. The glass tube 102 is rotated by the holder 130 around its central axis D while being viscously deformable by the preceding heating station 202, while the separation burner 348 engages 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 separates the partially molded glass article from the glass tube 102. Once separated from the glass tube 102, the partially molded article can be transferred to the secondary turret 114 (Figure 1) or discharged from the converter 100. Although shown as a thermal separation station in Figure 7, the separation station 206 may also be a non-thermal separation station, such as a separation station using cutting and breaking techniques, which may be used for syringes and cartridges, for example.

[0088] Similar to the heating station 202, the separation station 206 may also include a heating element positioning device 318 coupled to the separation burner 348. The heating element positioning device 318 may be operable to position the separation burner 348 relative to the glass tube 102 in the separation station 206 in a vertical direction (e.g., in the + / -Z direction of the coordinate axes in Figure 3), a horizontal direction (e.g., in the XY plane identified by the coordinate axes in Figure 7), or a combination of these directions. The heating element positioning device 318, fuel control valve 310, oxygen control valve 312, air control valve 314, or a combination thereof may be communicatively coupled to a control system 402 (Figure 3) to enable the control system 402 to control the vertical position, horizontal position, heat output, or a combination thereof of the separation burner 348. If the separation station 206 is a chiseling and breaking separation station, the separation station 206 may include one or more chiseling tools and / or breaking tools, and may further include tool actuators that can operate to change the position of the chiseling tools and / or breaking tools.

[0089] Referring again to Figure 2, in this embodiment, the converter 100 may include a drilling station 212. The drilling station 212 may be located on the main circuit 116 downstream of the separation station 206 in the translational direction 222 of the main turret 108. At the drilling station 212, the meniscus of the glass tube 102, which can be pre-formed within the separation station 206, may be drilled, thereby reopening the processed end of the glass tube 102. Referring now to Figure 8, one embodiment of the drilling station 212 of the converter 100 is schematically depicted. The drilling station 212 may be located behind the separation station 206 in the translational direction 222 of the main turret 108. As previously described, the thermal separation of the article 103 from the glass tube 102 within the separation station 206 may form a glass meniscus 350 over the processed end 150 of the glass tube 102. At the drilling station, a meniscus 350 is drilled at the processed end 150 of the glass tube 102 in preparation for forming the following article.

[0090] In embodiments, the drilling station 212 may include a drilling burner 352. The drilling burner 352 may be positioned below the processed end 150 of the glass tube 102 and oriented toward the processed end 150 of the glass tube 102. The drilling burner 352 may be fluidly coupled to one or more of the following: a fuel gas supply source 304, an oxygen supply source 306, an air supply source 308, or a combination thereof. The fuel gas supply source 304, the oxygen supply source 306, and the air supply source 308 were previously considered in relation to the burner 302 in Figure 3. The drilling station 212 may also include a fuel gas control valve 310, an oxygen control valve 312, and / or an air control valve 314 for controlling the heat output from the drilling burner 352. As the main turret 108 indexes the glass tube 102 into the drilling station 212, the flame from the drilling burner 352 heats the glass meniscus 350, melts the meniscus 350, drills through the meniscus 350, and reopens the processed end 150 of the glass tube 102. In embodiments, the meniscus 350 may be drilled by directing a flow of gas, such as compressed air, nitrogen, argon, or other gas, through or across the meniscus 350. In embodiments, mechanical means or other methods may be used to drill the meniscus 350 instead of using the drilling burner 352.Various methods for piercing the Meniscus 350 are described in U.S. Patent No. 10,968,133, granted on April 6, 2021, entitled "Methods for minimizing SHR in glass articles by producing a gas flow during pharmaceutical part converting," concurrently pending U.S. application No. 16 / 197,187, filed on November 20, 2018, entitled "SYSTEMS AND Methods for minimizing SHR from piercing during pharmaceutical part converting using a gas flow," concurrently pending U.S. application No. 16 / 197,971, filed on November 21, 2018, entitled "systems and Methods for minimizing SHR from piercing during pharmaceutical part converting using negative pressure evacuation," and concurrently pending U.S. application No. 16 / 198,041, filed on November 21, 2018, entitled "Systems and Methods for minimizing SHR from piercing from pharmaceutical part converting using pulsed The details of the ejection are disclosed in each specification, and all of their contents are incorporated herein by reference. Positioning devices, control valves, and other control devices may be incorporated into the drilling station 212 and may be communicably coupled to a control system 402 (Figure 1) to control various operating parameters of the drilling station 212.

[0091] Referring again to Figure 2, the converter 100 may further include a measuring station 218, where at least one measuring device may be used to measure one or more attributes of the glass tube 102, such as diameter and thickness, or one or more dimensions of feature parts of the glass article 103 formed by the forming station 204. Attributes of the glass article 103, including feature part dimensions, may include, but are not limited to, flange thickness, flange length, neck length, neck thickness, overall article height, flange inner diameter, flange outer diameter, flange height, top height, bottom flange angle, top flange angle, eccentricity, article inner or outer diameter, shoulder thickness, shoulder angle, shoulder radius, other feature part dimensions, or combinations thereof. One or more appearance attributes of the glass tube 102 or glass article 103 may also be evaluated at the measuring station 218. Appearance attributes may include, but are not limited to, defects in one or more feature parts of the glass article 103 (e.g., defects in the flange, neck, etc.), overall desirability, or combinations thereof. The overall desirability may be a composite characteristic based on several other dimensions or appearance attributes measured for the glass article 103. One or more measuring stations 218 may be located in the main circuit 116, the secondary circuit 118, or both. In embodiments, the measuring station 218 may be positioned in the main circuit 116 immediately after the last forming station 204 so that dimensions are measured while the glass tube 102 is still at a high temperature. Alternatively or in addition to this, in embodiments, the measuring station 218 may be positioned behind one or more cooling stations 210 to measure the dimensions of the glass tube 102 and / or glass article 103 at a lower temperature. In embodiments, the secondary circuit 118 of the converter 100 may include the measuring station 218.

[0092] Referring here to Figure 9, one embodiment of the measurement station 218 is schematically depicted. The measurement station 218 may include one or more measuring devices 360 positioned to measure one or more attributes of the glass tube 102 and / or the glass article 103. The attributes may include one or more physical dimensions, one or more appearance characteristics, or both of the glass tube 102 and / or the glass article 103. The measuring devices 360 may be communicatively coupled to a control system 402 to transmit information to the control system 402 regarding one or more attributes of the glass tube 102 and / or the glass article 103. The measuring devices 360 in the measurement station 218 may be any of the measuring devices described herein. In embodiments, the measuring device 360 ​​may be a thermal imaging device. Examples of thermal imaging devices for measuring the attributes and characteristics of the glass tube 102, or the feature formed at the processed end 150 of the glass tube 102, can be found in U.S. Patent No. 10,773,989, granted on September 15, 2020, titled "SYSTEMS AND METHODS FOR MEASURING THE TEMPERATURE OF GLASS DURING TUBE CONVERSION," the entirety of which is incorporated herein by reference.

[0093] Referring again to Figure 2, one or more cooling stations 210 may be positioned behind the main turret 108 of the molding station 204 in the translational direction 222. The main circuit 116 may also include a tube loading station 214 for loading raw materials for new lengths of glass tubes 102 from the glass tube loading turret 110 to the main turret 108 (Figure 1).

[0094] Figures 3 to 9 contain schematic illustrations of several different examples of processing stations 106 that may be used in the converter 100. However, it should be understood that other processing stations 106 having different structures, combinations of structures, or functions may be used to achieve the desired conversion of the glass tube 102 into one or more glass articles. The preceding description of the processing stations 106 of the main circuit 116 and the secondary processing station 112 of the secondary circuit 118 may represent a typical converter 100 for producing vials from the glass tube 102. However, it should be understood that more or fewer processing stations 106 and secondary processing stations 112 may be used to produce vials having different shapes or features, or other glass articles such as cartridges, syringes, ampoules, or other pharmaceutical glass articles. In addition, it should be understood that the processing stations 106 and secondary processing stations 112 may be arranged in any of several different orders and / or configurations to produce glass articles that are shaped differently.

[0095] Referring again to Figure 1, as previously discussed, the converter 100 may further include a control system 402 communicatively coupled to the converter 100 and at least one measuring device 360. The control system 402 may include one or more processors 404, one or more memory modules 406 communicatively coupled to the processors 404, and machine-readable and executable instructions 408 stored in at least one memory module 406. When executed by at least one processor 404, the machine-readable and executable instructions 408 can cause the control system 402 to perform any of the method steps disclosed herein and / or operate any of the processing stations 106 of the converter 100, the measuring device 360, or other control devices.

[0096] Referring here to Figure 10, the glass tube 102 may be a long, hollow cylindrical tube made of glass. The glass tube 102 may have a circular cross-sectional shape and may have an outer surface 140, an inner surface 146, and a thickness t. The thickness t of the glass tube 102 may be the radial distance between the inner surface 146 and the outer surface 140 of the glass tube 102. The glass tube 102 may have a length L in the + / -Z direction of the coordinate axes in Figure 10. The glass tube 102 may have an outer diameter OD, as shown in Figure 10. As previously considered, the glass tube 102 may be rotated about its central axis D throughout the conversion process. The processed end 150 of the glass tube 102 is the end of the glass tube 102 that is oriented in the -Z direction of the coordinate axes in Figure 10 when the glass tube 102 is fixed to the holder 130 of the converter 100. The unprocessed end of the glass tube 102 is the end opposite to the processed end 150 (i.e., the end of the glass tube 102 in the +Z direction of the coordinate axes in Figure 10).

[0097] Referring again to Figures 1 and 2, in the general operation of the converter 100 for producing glass articles 103 from glass tubes 102, the main turret 108 may index or move the glass tubes 102, which are fixed in the holder 130, into processing stations 106. At each of the processing stations 106, specific operations, such as heating, molding, drilling, separation, cooling, dropping, feeding, and measurement, may be performed on the glass tubes 102. The converter 100 may be tuned so that all of the processing stations 106 complete their operations within the dwell time. At the end of the dwell time, the main turret 108 may index the glass tubes 102 to the next processing station 106 during the indexing time. In the case of an indexing converter, the total time per part per station used in this disclosure is the sum of the dwell time and the indexing time.

[0098] In an embodiment, the converter 100 may be a continuous converter capable of operating to move the glass tube 102 and holder 130 continuously through a plurality of processing stations 106. In an embodiment, heating elements, burners, molding tools, measuring devices, and other elements of the conversion process may move with the glass tube 102 as it passes through the processing stations 106. For both indexing and continuous converters, the “active time” of a processing station is the duration for which the glass tube 102 is maintained to engage with at least one heating element, at least one molding tool, at least one cooling nozzle, or other device while it is within the processing station 106.

[0099] An example of a converter 100 for converting glass tubes 102 to glass vials includes Vial Forming Machine Models RP16 or RP18 with an Automatic Tube Feeder manufactured by AMBEG Dr.J.Dichter GmbH, which includes 16 processing stations 106 and 8 secondary processing stations 112 in a main circuit 116. Other examples include Vial Forming Machine Model RP32, manufactured by AMBEG Dr.J.Dichter GmbH, which has 32 processing stations 106 in a main circuit 116 and two secondary circuits 118, each having 8 secondary processing stations 112, and the Zeta 098 Vial Forming Machine manufactured by Euromatic SRL, which has 36 processing stations. Another example may include the Zeta 103 Cartridge Forming Machine, manufactured by Euromatic SRL, which is a converter for converting glass tubes to glass cartridges. Cartridge converters may have similar characteristics to the vial converters described earlier, but can be used to produce glass articles having a cartridge form factor instead of vials.

[0100] Although described in the context of a converter 100 for producing glass vials from glass tubes 102, it should be understood that the converter 100 may be configured to produce one or more other articles, such as other types of pharmaceutical containers or articles, by changing the order or configuration of the molding tool 324 and / or processing stations 106 in the main circuit 116, or by changing the secondary processing stations 112 in one or more secondary circuits 118. Pharmaceutical articles may include, but are not limited to, vials, vacuuminers, cartridges, syringes, ampoules, bottles, or other glass pharmaceutical articles.

[0101] Current conversion methods for producing glass articles from glass tubes using converter machines have long relied on manual observation and manual adjustment of glass article attributes (or pseudo-manual adjustment, as the actuator itself is a dial-adjustable stage or a servo driven by a PLC). For example, conversion in glass vial production has long relied on manual observation of vial height attribute behavior followed by manual adjustment. The conversion process can usually be a gradual drift, but occasionally it can be interrupted by abrupt shifts in the measured attributes of the glass article. Furthermore, a typical converter has many setpoints, though not limited to, gas flow rate, gas mixing ratio, burner position, forming tool wheel and pin position, contact timing, tube length drop height, and other setpoints that must be determined in efforts to achieve an acceptable yield. Even after the nominal setpoints have been determined, changes in incoming material, component wear, and many other disturbances necessitate real-time adjustments of the actuator setpoints themselves to compensate for the process. The sources of disturbances are often unknown, and even when known, some are not economically feasible to eliminate compared to the development and application of feedback control solutions. Therefore, the maximum achievable yield can fluctuate over time and depends on the evolution of the shape of the distribution of various measurement attributes of the glass article over time.

[0102] As a non-limiting example, if the glass article is a glass vial, the vial height is one critical dimension of the glass vial to maintain within specifications. Referring again to Figure 6, immediately before or after the completion of the flange forming process for producing the flange 144 of the glass vial, the gripper 336 of the chuck 334 is temporarily loosened to allow the glass tube 102 to drop a distance corresponding to the intended height of the final glass vial until the processed end 150 of the glass tube 102 contacts the mechanical stopper 330. The position of the mechanical stopper 330 may be set by a stopper positioning device 332, which may be a servo motor. In embodiments, the position of the mechanical stopper 330 generally has a direct relationship with the final height of the glass vial. The glass tube 102 then proceeds to the separation process and is moved to a secondary turret 114 (Figure 1) to form the bottom of the glass vial. Referring now to Figure 10, the resulting height H of the glass vial 141. A This can vary considerably, and this variability may be a function of the specific bottom forming chuck used. Due to variability between chucks, the distribution at the measured height of the glass vial 141 may be a tail-heavy distribution. Another non-limiting example is the inner flange diameter D F , or other measurement attributes of the glass tube 102 and / or glass article 103. The distribution of various measurement attributes may have a non-Gaussian shape, such as being tail-heavy or multi-peaked, which may make setpoint control difficult. The distribution of measurement attributes may also be subject to sudden shifts, for example, due to maintenance operations, e.g., replacement of worn parts, cleaning operations, or other maintenance activities, but not limited to these.

[0103] This application relates to a method for controlling one or more operations of a converter by shifting the distribution of measurement attributes in order to obtain the maximum yield of conforming products. In the control method disclosed herein, the distribution of measurement attributes is shifted between upper and lower specification limits. The distribution shift control method can produce the maximum yield of conforming glass articles regardless of the shape of the distribution of measurement attributes and regardless of whether the distribution is highly distorted. The control method disclosed herein can be applied to any measurement attribute of a glass article. As a non-limiting example, the control method can be used to the height and inner flange diameter of a glass article, which is a glass vial, among other attributes.

[0104] Referring here to Figure 1, according to embodiments disclosed herein, a method for controlling a converter 100 for producing glass articles 103 from a glass tube 102 includes operating the converter 100 to produce glass articles 103 from the glass tube 102. The converter 100 comprises a plurality of processing stations 106, and operating the converter 100 includes sequentially translating the glass tube 102 through each of the plurality of processing stations 106. The method may further include measuring the attributes of the glass articles 103 during or after conversion, the attributes undergoing gradual changes over time, sudden changes, or both. The method may further include developing an attribute distribution from the measured attributes and shifting the attribute distribution within a specified range of attributes, shifting the attribute distribution increases the yield of the glass articles 103. Shifting the attribute distribution within a specified range may include adjusting at least one process setting of the converter, adjusting at least one process setting shifts the attribute distribution.

[0105] The control method disclosed herein is an enhancement of conventional feedback control of a process based on attribute specification values. Conventional feedback control methods based on attribute specification values ​​generally include measuring an attribute downstream of the process, calculating an error between the measured value of the attribute and a target value of the attribute corresponding to a fixed specification value of the attribute from the product specification, and then developing a control response based on the error between the measured value and the target value. The method disclosed herein focuses on shifting the target value of the attribute within the specification range, thereby ensuring that the maximum number of glass articles fall within the specification range and thereby improving the yield of glass articles. Therefore, the target value may be shifted away from the attribute specification value from the product specification in order to improve the yield of glass articles.

[0106] In conventional feedback control systems, the target value of an attribute is obtained based on the specification value of the product specification, which may be constrained between the upper and lower specification limits of the attribute. For attributes with a normal distribution centered on the mean, controlling the mean of the attribute distribution to a target value equal to the specification value ensures that the maximum number of glass articles fall between the upper and lower limits of the specification range. These conventional control methods are generally symmetric and effective for normal attribute distributions centered on the mean. However, when the distribution of measured attribute values ​​is non-normal, for example, asymmetric (e.g., heavy-tailed), multimodal, or has other irregular patterns, feedback control based on the specification value of the attribute can still result in a significant percentage of non-conforming glass articles (e.g., a percentage of glass articles with measured attributes outside the specification range of the attribute).

[0107] This method determines a target value for an attribute between the upper and lower limits of a specification range by considering the attribute distribution as a whole and the shape of the attribute distribution, and shifting the attribute distribution so that as many glass articles as possible fall within the specification range, regardless of whether the attribute's specification value is between the upper and lower limits of the specification range. In other words, instead of setting the target value of an attribute to a specification value from the product specification, the method of this disclosure operates to obtain the maximum percentage of the measured attribute in the attribute distribution within the specification range (e.g., increasing or maximizing the yield of glass articles) by shifting the target value itself within the specification range and relative to the specification value from the product specification. Once a target value for an attribute that increases the yield of glass articles is determined, a control response is developed to adjust one or more process settings to shift the attribute distribution to correspond to the new target value. The control response that shifts the attribute distribution can then be determined through a variety of control methodologies, including, but not limited to, PID control, read / lag control, model predictive control, or other control methods.

[0108] In the method of this disclosure, adjusting the process setting(s) shifts the mean of the attribute distribution up or down within the specification range to the updated target value of the attribute, which in turn shifts all other measurements within the attribute distribution within the specification range. Thus, the entire attribute distribution is moved within the specification range, increasing the number of conforming glass articles having attributes that fall within the specification range. Although considered in the context of the mean of the attribute distribution, it is understood that shifting the attribute distribution may be based on other characteristics of the attribute distribution, such as, but not limited to, the median, maximum measurement, minimum measurement, standard deviation, spread between the minimum and maximum measurements, or other characteristics of the attribute distribution.

[0109] The control methods disclosed herein may be well suited to processes where dynamics in the control relationship between process settings and measured attributes can be ignored. This is typical in discrete component manufacturing, such as the manufacture of pharmaceutical vials or other pharmaceutical containers, but is not limited to these. The control methods disclosed herein may also be applicable to processes where the control relationship between process settings and measured attributes is stable over time. Slow drifts in the control relationship are acceptable in additional ways to periodically recharacterize the control relationship. The control methods disclosed herein may be suitable for measurable quality attributes so that estimates of attribute distributions can be developed. Finally, the control methods disclosed herein may be suitable for measured attributes having upper specification limits, lower specification limits, or both upper and lower specification limits.

[0110] The method disclosed herein may enable an increase in the yield of conforming glass articles by shifting the attribute distribution to fit within the maximum number of measured attributes within a distribution within the specification range. The control method disclosed herein can be applied to attribute distributions of any shape because the shift acts on the direct set of measurements used to estimate the true underlying attribute distribution. The method disclosed herein reduces reliance on human intervention and thus reduces process variability caused by operator variability. The control method can be implemented in a fully automated manner or incorporated into a control strategy with human operators in a control loop. Full automation of the control method disclosed herein may improve efficiency by eliminating the need for operators to spend time "checking what the current state is," however, full automation of the control method may be less context-aware. Therefore, full automation of the control method may be applicable to a conversion process where the main assignable causes of nonconforming products have already been eliminated. Some anomalous behavior of converter 100 may be difficult to capture by algorithms but can be observed and recorded by human operators. The control methods disclosed herein can be adapted to allow varying degrees of human interaction, which can provide an opportunity to observe these abnormal behaviors and explain them when controlling the transformation process. The control methods can be applied to a single attribute of a glass article or to multiple attributes of a glass article.

[0111] A control method disclosed herein for producing glass articles from a glass tube can be carried out using a system comprising a converter, one or more measuring devices, one or more control devices, and a control system communicatively coupled to the converter, measuring devices, and control devices. Referring again to Figures 1 and 2, a system 400 for producing a plurality of glass articles 103 from a glass tube 102 comprises a converter 100 having a plurality of processing stations 106, for example, but not limited to, at least one heating station 202, at least one forming station 204, and a separation station 206. In embodiments, the converter 100 may further include a tube length drop station 220. As previously discussed, the converter 100 may be operable to translate the glass tube 102 through each of the plurality of processing stations 106. The converter 100 may include a plurality of holders 130. Each of the holders 130 may be operable to fix the glass tube 102 and rotate the glass tube 102 around its central axis D. Sequentially translating the glass tube 102 through each of the processing stations 106 can shape one or more feature portions of the glass article 103 and separate the glass article 103 from the processed end 150 of the glass tube 102. It is understood and intended that the converter 100 may include any of the feature portions, processing stations, or operating parameters described herein earlier for the converter 100. The system 400 further includes at least one measuring device 360 ​​operable to measure one or more attributes of each glass article 103 produced from the glass tube 102. The converter 100 further includes at least one control device (not shown in Figure 1 or 2) operable to change process settings affecting the attributes of the glass article 103. The converter 100 may further include a control system 402 communicatively coupled to the converter 100, the at least one measuring device 360, and the control device. The control system 402 may be operable to perform one or more of the method steps disclosed herein.

[0112] Referring again to Figure 1, the measuring device 360 ​​may be positioned to measure the attributes of the glass article 103 during or after conversion. The measuring device 360 ​​may enable 100% online inspection of various dimensional and appearance attributes of the glass tube 102, the glass article 103, or both, in order to provide the system 400 with real-time data on the measurement attributes of the glass article and / or glass tube 102. In embodiments, the measuring device 360 ​​may be coupled to one or more of the main turret 108, secondary turret 114, processing station 106, or a combination thereof, so that the measuring device 360 ​​may be able to operate to measure the attributes of the glass article 103 and / or glass tube 102 during the conversion process on the converter 100. The measuring device 360 ​​may be located within one or more measuring stations 218, which may be in the primary circuit, the secondary circuit, or both. In addition to or instead of this, in embodiments, the converter 100 may include one or more measuring devices 360 positioned at one or more processing stations 106 other than the measuring station 218, for example, but not limited to, a heating station 202, a molding station 204, a separation station 206, a cooling station, a drilling station, or other types of processing stations. In addition to or instead of this, one or more of the measuring devices 360 may be coupled to one of a plurality of holders 130 and translated through the plurality of processing stations 106 using the holder 130. In embodiments, the converter 100 may include a plurality of measuring devices 360, each of which may be coupled to a processing station 106 and / or to one of a plurality of holders 130 for translation through the plurality of processing stations 106 using the holder 130 and glass tube 102. In addition to or instead of this, the measuring devices 360 may be located downstream of the converter 100, for example, at a quality control station downstream of the converter 100. In the embodiment, the measuring device 360 ​​may be located downstream of the converter 100, for example, after the glass article 103 has been removed from the secondary turret 114, or after an annealing process (not shown) located downstream of the converter 100.

[0113] The measuring device 360 ​​may be operable to measure one or more attributes of the glass tube 102, one or more attributes of feature parts of a partially formed glass article at the processed end 150 of the glass tube 102, one or more attributes of each of the glass articles 103 produced from the glass tube 102, or a combination thereof. The attributes of the multiple glass tubes 102, glass articles 103, partially formed glass articles 103, or a combination thereof may include one or more temperatures of the glass tube 102, one or more dimensions of the glass tube 102, one or more dimensions of the multiple glass articles 103, or feature parts of the partially formed glass articles 103 formed at the processed end 150 of the glass tube 102, one or more appearance attributes of the multiple glass articles 103, or a combination thereof. In embodiments, the measuring device 360 ​​may be positioned and operable to measure one or more attributes of a glass preform at the processed end 150 of the glass tube 102. The glass preform refers to the heated portion of the glass tube 102 at the processed end 150 of the glass tube 102, after the heating station 202 and before the molding station 204. In the embodiment, the measuring device 360 ​​may be positioned and operable to measure one or more physical dimensions of the glass article 103, feature parts of the partially molded glass article 103, or a combination thereof.

[0114] One or more measuring devices 360 may include any measuring devices capable of measuring one or more dimensions, temperature, or appearance attributes of the glass tube 102 and / or glass article 103 produced therefrom. Measuring devices 360 may include, but are not limited to, optical measuring systems, laser measuring devices, measuring devices using sound waves or other electromagnetic waves, or other measuring techniques. In embodiments, measuring devices 360 may include a thermal imaging system, such as the thermal imaging system disclosed in U.S. Patent No. 10,773,989, filed March 22, 2018, entitled “SYSTEMS AND METHODS FOR MEASURING THE TEMPERATURE OF GLASS DURING TUBE CONVERSION,” the entire contents of which are incorporated herein by reference. The thermal imaging system may operate to measure one or more temperatures and / or dimensions of the glass tube 102, the glass article 103, or both, while the glass tube 102 is heated and formed into the glass article 103, or afterward. In addition to or instead of the above, the measuring device 360 ​​may include one or more dimensional measuring systems, such as a visual imaging system, a laser reflectometer, a laser gauge, an optical micrometer, or one or more other measuring devices capable of measuring one or more dimensions of the glass tube 102, a feature portion of a partially molded glass article, a finished glass article 103, or a combination thereof. Other available measuring devices 360 are intended for determining one or more temperature, dimensions, appearance attributes, or combinations thereof of the glass tube 102, the glass article 103, or both.

[0115] Referring here to Figures 1 to 8, the control devices of the converter 100, which can be communicatively coupled to the control system 402, may include, but are not limited to, a heating element positioning device 318, a fuel gas control valve 310, an oxygen control valve 312, an air control valve 314, a molding tool actuator 326, outer molding tool actuators 326a and 326b, an inner molding tool actuator 328, a stopper actuator 332, a chuck 334 of the holder 130, a main turret drive motor, a drive motor operably coupled to the holder 130 for the rotation of the glass tube 102, a timer, a ventilation system, other control devices, or a combination thereof. The number and type of control devices may depend on the specific converter 100 used and the number and type of processing stations 106 employed by the converter 100.

[0116] Referring again to Figure 1, the system 400 for producing multiple glass articles from a glass tube 102 may further include a control system 402 communicatively coupled to the converter 100. Specifically, the control system 402 may also be communicatively coupled to measuring devices 360 and various control devices in the processing station 106 of the converter 100. The control system 402 may include one or more processors 404, one or more memory modules 406 communicatively coupled to the processors 404, and machine-readable and executable instructions 408 stored in the memory modules 406. When executed by the processors 404, the machine-readable and executable instructions 408 may cause the system 400 to perform any of the actions and / or method steps disclosed herein, even if not explicitly stated in the context of the machine-readable and executable instructions 408. In the embodiment, when executed by the processor 404, the machine-readable and executable instruction 408 causes the system 400 to at least automatically measure the attributes of the glass article 103, develop an attribute distribution based on the measured values ​​of the attributes of the glass article 103, determine whether a shift in the attribute distribution within the specified range of attributes increases the yield of the glass article 103, and, if the shift in the attribute distribution increases the yield of the glass article, shift the attribute distribution within the specified range of attributes.

[0117] Referring here to Figure 11, in an embodiment, the system 400 may further include a display 430 operable to display a graphical user interface 432. The display 430 may be directly coupled to the control system 402 or may communicate electronically with the control system 402 through a network 410. The display 430 may be a touchscreen or may include one or more input devices (not shown) that can enable a user to input information into the graphical user interface 432. The graphical user interface 432 may be operable to display information about the control system 402 and control sequences. The graphical user interface 432 may also be operable to receive input from a user (e.g., a machine operator) and transfer user input to the control system 402. In an embodiment, the system 400 may further include one or more external computing devices 420 operable to communicate with the control system 402 through a network 410. One or more of the external computing devices 420 may be configured to perform one or more of the actions and / or method steps disclosed herein, for example, but not limited to, processing attribute measurements to develop attribute distributions, recalculating control relationships between attributes and process settings, or other operations outside of the control system 402.

[0118] Referring here to Figure 12, a flowchart of one embodiment of Method 500 for controlling a converter for producing glass articles from glass tubes is depicted. Method 500 may include in step 502 operating the converter to produce glass articles from glass tubes, the converter comprising a plurality of processing stations, and operating the converter includes sequentially translating the glass tubes through each of the plurality of processing stations. Operating the converter in step 502 may include any of the process steps disclosed herein for producing glass articles from glass tubes. Method 500 may further include in step 504 measuring one or more attributes of the glass articles and / or glass tubes during or after the conversion. Method 500 may further include in step 506 developing an attribute distribution from the attribute measurements. The method may further include shifting the attribute distribution within the specification range of the attributes (steps 508-516), shifting the attribute distribution increases the yield of glass articles. Shifting the attribute distribution may include determining in step 508 whether the shift in the attribute distribution increases the yield of the glass articles. Step 510 may be a decision block. If in step 510 the shift does not increase the yield, or the cost of making the shift is greater than the benefit, the method may return to operating the converter in step 502 and measuring the attributes of the glass tubes and / or glass articles in step 504. If in step 510 the shift increases the yield of the glass articles, the method proceeds to determining the shift in the attribute distribution in step 512. After determining the shift in the attribute distribution that increases the yield in step 512, the method may further include determining one or more updated process settings corresponding to the desired shift in the attribute distribution in step 514. Method 500 may further include changing one or more of the process settings to the updated process settings in step 516.

[0119] The glass article 103 produced from the glass tube 102 by the conversion process may be a pharmaceutical container such as a vial, vacuum inlet, syringe, ampoule, cartridge, bottle, or other glass article, but is not limited to these. In an embodiment, the glass article 103 may be a glass vial. Referring again to Figure 10, the glass article 103 may be a glass vial 141. The glass vial 141 may comprise a shoulder portion 142 and a flange 144 formed at one end of the glass vial 141, and a bottom portion 146 at the other end of the glass vial 141. The glass vial 141 may include a heel portion 148 that forms a transition between the side wall 149 and the bottom portion 146 of the glass vial 141. The flange 144 may include an opening 152 that provides access to the internal volume of the glass vial 141. Although this method is described herein in the context of pharmaceutical glass vials, it is understood that the method disclosed herein may be applied with the expectation of achieving the same level of success as with other glass articles, such as syringes, ampoules, cartridges, bottles, vacuuminers, or other glass articles.

[0120] The attributes measured by the measuring device 360 ​​may include the attributes of the glass tube 102, the attributes of the glass article 103, or both. The attributes of both the glass tube 102 and the glass article 103 may undergo gradual changes, sudden changes, or both over time. The attributes of the glass article 102, the glass article 103, or both may be subject to a specification range that defines the conforming product. The specification range for each attribute may include an upper specification limit, a lower specification limit, or both upper and lower specification limits.

[0121] The attributes of the glass tube 102 may include, but are not limited to, the outer diameter, inner diameter, wall thickness, temperature at one or more locations, or other attributes. The attributes of the glass article 103 may include, but are not limited to, one or more feature dimensions such as flange thickness, flange height, neck height, neck outer diameter, neck inner diameter, overall article height, flange inner diameter, flange outer diameter, top height, bottom flange angle, top flange angle, eccentricity, article inner or outer diameter, shoulder thickness, shoulder angle, shoulder radius, other feature dimensions, or combinations thereof. Attributes may differ for different types of glass articles. For example, in the case of a syringe, attributes including physical dimensions may include the barrel inner or outer diameter, tip dimensions, end flange dimensions, body height, tip height, overall height, or other attributes. A cartridge may have similar attributes to a glass article, except that it has an open end on the opposite side of the flange instead of a closed bottom. Other glass articles may have one or more other physical attributes that can be measured in this method. The attributes of the glass tube 102 and / or glass article 103 may also include one or more appearance attributes.

[0122] In embodiments, the glass article 103 may be a glass vial, and its attributes may be selected from flange thickness, flange height, flange inner diameter, flange outer diameter, bottom flange angle, top flange angle, neck height, neck outer diameter, neck inner diameter, overall article height, top height, eccentricity, side wall inner or outer diameter, shoulder thickness, shoulder angle, shoulder radius, other characteristic part dimensions, or a combination thereof. In embodiments, the glass article 103 may be a glass vial, and its attributes may be overall vial height, flange inner diameter, or both.

[0123] The control system 402 may be operable to receive specifications for the glass article 103 to be produced, and the specifications may include one or more specification values ​​and specification ranges for attributes of the glass article 103, the glass tube 102, or both. For example, in embodiments, the specification range for the attributes of the glass article 103 may include one or more upper or lower specification limits based on specification values ​​from the international standard relating to the glass article 103, for example, but not limited to, ISO 8362-1, “Injection Containers and Accessories - Part 1: Injection Vials Made of Glass Tubing”, 3rd edition, 2009-12-15, the entire content of this international standard is incorporated herein by reference. Table 1 below provides exemplary specifications from ISO 8362-1, which provide dimensions for injection vials made from glass tubing material that accommodate a neck finish without blowback (i.e., Model A). [Table 1]

[0124] As previously discussed, the methods disclosed herein may include measuring one or more attributes of a plurality of glass tubes 102 and / or glass articles 103, or of the glass tubes 102, glass articles 103, or both. The attributes may be measured using a measuring device 360, which may be located in one of the processing stations 106 of the converter 100, coupled to a holder 130 of the converter, or located downstream of the converter 100. In embodiments, the method may include measuring one or more attributes of the glass article 103 after forming one or more feature portions of the glass article 103 at the processed end 150 of the glass tube 102. In embodiments, the attributes of the glass article 103 may be measured using a measuring device 360 ​​located in a processing station 106 downstream of the forming station, or coupled to a holder 130 of the converter. In the embodiment, operating the converter 100 includes shaping one or more feature portions of the glass article 103 at the processed end 150 of the glass tube 102, and after shaping, separating the glass article 103 from the processed end 150 of the glass tube 102, and the method may include shaping one or more feature portions of the glass article 103, separating the glass article 103 from the processed end 150 of the glass tube 102, and then measuring the attributes of the glass article 103.

[0125] In embodiments, the method may include measuring the attributes of the glass article 103 after conversion for producing a glass article 103 from the glass tube 102, for example, after the glass article 103 has been discharged from the converter 100. In embodiments, the method may further include annealing the glass article 103 after it has been discharged or removed from the converter 100, and measuring the attributes of the glass article 103 may be performed after the glass article 103 has been annealed. In embodiments, the measuring device 360 ​​may be located downstream of the annealing process.

[0126] The attributes can be measured for a sufficient number of glass articles 103 to generate an attribute distribution that approximates the true distribution of attributes. The true distribution of attributes refers to a theoretical attribute distribution that represents an infinite number of measurements of the attributes. The number of glass articles 103 whose attributes are measured to generate the attribute distribution may be referred to herein as the “lookback window”. In embodiments, the lookback window may include a statistically relevant number of glass articles 103. In embodiments, the method may include measuring the attributes of several glass articles 103 within a lookback window of 50 or more, 60 or more, 100 or more, or even 200 or more. In embodiments, the method may include measuring the attributes of a number of glass articles 103 for each lookback window, such as 50-2000, 50-1000, 50-500, 50-200, 50-100, 60-2000, 60-1000, 60-500, 60-200, 60-100, 100-2000, 100-1000, 100-500, 100-200, 200-2000, 200-1000, or 200-500. In embodiments, the number of glass articles whose attributes can be measured may be greater than 2000.

[0127] After measurement, the attribute measurements for each glass article 103 may be transmitted to the control system 402. The attribute measurements may be stored in one or more memory modules 406 of the control system 402 or an external computing system 420. The attribute measurements may be stored in a relational database on the memory module 406 of the control system 402 or the external computing system 420. Each glass article 103 may be assigned a unique identifier, and the relational database may associate each glass article through the unique identifier with a specific holder 130, operating conditions, and process settings for producing the glass article 103. The unique identifier and the relational database may be part of a parts tracking system that can be used to track each individual glass article throughout the conversion process.

[0128] As previously discussed, after measuring the attributes of multiple glass articles, the method may include determining the attribute distribution from the attribute measurements within a lookback window. The attribute distribution may be derived using statistical methods performed by the control system 402. In embodiments, the control system may upload the attribute measurements to an external computing device 420, which may generate the attribute distribution from the attribute measurements. The attribute distribution may deviate from a normal distribution. In embodiments, the attribute distribution may be an asymmetric distribution, such as having heavy tails, being multimodal, or having any other irregular non-Gaussian distribution shape. In embodiments, the attribute distribution may further include indication of the specification range of the attributes.

[0129] After preparing the attribute distribution, the methods disclosed herein may include determining a shift in the attribute distribution within a specification range that increases the yield of glass articles. Determining a shift in the attribute distribution within a specification range may include comparing the attribute distribution to a specification range and determining whether shifting the attribute distribution in one direction or the other increases the number of conforming glass articles within the specification range. The step of determining a shift in the attribute within a specification range that increases the yield of glass articles may be performed by a control system 402 or an external computing device 420. In embodiments, the method may include determining whether a shift in the attribute distribution within a specification range increases the yield of glass articles, and if the shift in the attribute distribution increases the yield of glass articles, shifting the attribute distribution within the specification range. In embodiments, the method may include determining whether a shift in the attribute distribution does not increase the yield, and if the shift in the attribute distribution does not increase the yield, maintaining the process settings at the current setpoint.

[0130] Determining whether a shift in the attribute distribution within the specification range increases the yield of glass articles may involve performing a series of simulations to empirically determine which shifts increase yield, or calculating which shifts increase yield using a first principle or statistical method. In embodiments, determining whether a shift in the attribute distribution within the specification range increases the yield of glass articles may involve performing a series of simulations to generate several simulated shifts, where the attribute distribution is numerically shifted in direction (i.e., towards the upper specification limit or the lower specification limit), magnitude, or both. For each simulated shift, the yield of glass articles is calculated. The yield of glass articles refers to the proportion of glass articles that fall within the specification range of the measured attribute, relative to the total number of glass articles produced. The simulated shift that yields the maximum yield of glass articles may be referred to as the best simulation. The best simulation may represent the shift in the attribute distribution within the specification range that increases the yield of glass articles to the greatest extent.

[0131] In embodiments of the method, determining a shift in the attribute distribution within a specification range that increases the yield of glass articles may include performing a series of simulations in which, in each of the simulations, the attribute distribution is shifted by different magnitudes, directions, or both; determining the best simulation from the series, which is capable of producing the maximum yield of glass articles; and setting the magnitude and direction of the shift in the attribute distribution to be equal to the magnitude and direction corresponding to the best simulation. If none of the simulations result in an increase in the yield of glass articles, the current attribute distribution is the best, and the attribute distribution may not be shifted within the specification range. Shifting the attribute distribution may include determining the characteristics of the attribute distribution, such as, but not limited to, the mean, median, maximum, minimum, primary peak, secondary peak, standard deviation, or other characteristics, and then shifting the characteristics of the attribute distribution, thereby shifting the attribute distribution relative to the specification values ​​and specification ranges of the attributes.

[0132] In some examples, multiple shift simulations may yield similar or identical yields for the glass articles corresponding to the maximum yield. If multiple shift simulations yield the same or similar yields representing the greatest increase in the yield of the glass articles, the best simulation may be the shift simulation that is most robust to future changes in the attribute distribution, for example, changes caused by drift in attribute measurements, etc. In embodiments, the best simulation may be a shift simulation in which further changes or drifts in the attribute distribution result in a minimal decrease in the yield of the fitted glass articles.

[0133] In some examples, multiple shift simulations may result in a 100% yield of the glass article with respect to a particular attribute. In these cases, the best simulation is the shift simulation that allows for the largest offset or change in the attribute distribution while still maintaining a 100% yield of the glass article. In embodiments, if two or more of the shift simulations result in a 100% yield of the glass article, the best simulation may include a shift simulation that corresponds to the largest offset in the attribute distribution while still maintaining a 100% yield of the glass article. In embodiments, if two or more of the simulations may result in a 100% yield of the glass article, the best simulation may be the simulation in which the smallest absolute value of the difference between the measured value of the attribute distribution and the upper or lower limit of the specification range is maximized, and the yield of the glass article is 100%.

[0134] In some examples, the direction of future changes in the position of the attribute distribution relative to the specification range may be known. For example, tool wear and / or actuator wear may be expected to result in a drift of the attribute distribution relative to the specification range in the expected direction. The known drift may be described by shifting the attribute distribution closer to the upper or lower specification limit, depending on the direction of the expected drift in the attribute distribution, while still maintaining a 100% yield of the glass articles. In embodiments, two or more of several simulations may result in a 100% yield of the glass articles, the attributes may be known or expected to drift in a particular direction, the particular direction may be towards the upper or lower specification limit of the specification range, and the best simulation may result in a 100% yield of the glass articles and provide the maximum absolute difference between either the upper or lower specification limit and the measured attribute value closest to the upper or lower specification limit, respectively, in the particular direction of the expected drift. The closest measured attribute value is the measured attribute value in the attribute distribution closest to the specification limit in the direction of the expected drift. Therefore, the mean or average of the attribute distribution may be shifted to move far away from the specification limits in the direction of the expected drift, which may allow for the longest period during which the attribute distribution drifts within the specification range with 100% yield before it becomes necessary to shift the attribute distribution again.

[0135] Instead of empirically determining shifts in attribute distributions through multiple simulations, in embodiments, determining whether a shift in attribute distribution increases the yield of glass articles may involve analysis and / or calculation based on a first principle, a statistical method, or both, without performing a series of simulations. In embodiments, determining shifts in attribute distributions within a specification range that increase the yield of glass articles may involve analyzing the attribute distribution to determine the characteristics, relationships, or both that characterize the attribute distribution, and calculating from the characteristics, relationships, or both that characterize the attribute distribution the shifts in attribute distributions within a specification range that increase the yield of glass articles. Analyzing the attribute distribution to determine the characteristics, relationships, or both that characterize the attribute distribution involves applying a first principle, a statistical method, or both, to the attribute distribution.

[0136] In some cases, the benefits of shifting the attribute distribution within the specification range to increase yield may outweigh the costs of making the shift. In some cases, the benefits of increasing the yield of glass articles may be small and not outweigh the costs associated with applying the shift. The costs may include the undesirable consequence of diverting the operator's attention from other matters in order to pay attention to the shift in the attribute distribution. Therefore, when human operators are involved, shifting the attribute distribution within the specification range should only be recommended if the expected benefits from increased yield are greater than a threshold benefit; below this threshold, the costs outweigh the benefits. The costs may also be related to the impact of the shift in the attribute distribution on downstream processes or other attributes, e.g., causing changes in another measurable attribute that must be analyzed next.

[0137] In embodiments, after determining a shift in the attribute distribution within the specification range to increase the yield of glass articles, the method may further include determining whether the benefits of shifting the attribute distribution within the specification range to increase the yield outweigh the costs associated with making the shift. In embodiments, determining a shift in the attribute distribution within the specification range may further include determining whether the benefits of shifting the attribute distribution within the specification range are greater than the costs of shifting the attribute distribution, and if the benefits of shifting the attribute distribution are greater than the costs, advancing the shift in the attribute distribution by adjusting at least one process setting to shift the attribute distribution within the specification range, and if the benefits of shifting the attribute distribution are less than the expected costs, not shifting the attribute distribution and instead maintaining the process setting at the previous values.

[0138] Where it is determined that shifting attributes increases yield and the benefits of doing so outweigh the costs, the methods disclosed herein may further include applying a shift in the attribute distribution. Shifting the attribute distribution may include adjusting at least one process setting, and adjusting at least one process setting shifts the attribute distribution within the specification range. Adjusting at least one process setting may include determining an updated setpoint for at least one process setting and adjusting at least one process setting to the updated setpoint. In embodiments, shifting the attribute distribution may include adjusting multiple process settings, for example, determining an updated setpoint for each of the multiple process settings and then adjusting each of the multiple process settings to the updated process setting.

[0139] Updated setpoints for process settings can be determined from the magnitude and direction of shifts in the attribute distribution, as well as the control relationships between process settings and attributes. In embodiments, determining updated setpoints for at least one process setting may include determining shifts in the attribute distribution within the specification range that increase the yield of glass articles, and calculating updated setpoints for at least one process setting from the magnitude and direction of shifts in the attribute distribution, as well as the control relationships between at least one process setting and attributes. Updated setpoints for process settings can be determined using one or more control methodologies, including but not limited to proportional-integral-derivative (PID) control methods, lead / delay control methods, model predictive control methods, or other control methods.

[0140] The process settings may be any of the process settings associated with control devices that affect attributes measured during operation. The process settings may include, but are not limited to, the overall part speed, the rotational speed of the holder 130, the burner position in one or more heating stations 202, the burner contact time in the heating stations 202, the burner heat output in one or more heating stations 202, the position of the molding tool 324 in one or more molding stations 204, the contact timing between the molding tool 324 and the glass tube 102 in one or more molding stations 204 (i.e., total contact time, contact sequence, or both), the contact sequence between the molding tool 324 and the glass tube 102, the position of the mechanical stopper 330 in the tube length drop station 220 or molding station 204, other operating parameters, or a combination thereof. Referring to Figure 3, the burner position of the burner 302 in the heating station 202 may include the vertical position of the burner 302 relative to the glass tube 102 (e.g., in the + / -Z direction of the coordinate axes in Figure 3), the horizontal position (e.g., in the XY plane of the coordinate axes in Figure 3), or a combination thereof, controlled by the burner positioning device 318. The burner heat output of the burner 302 in the heating station 202 may include the position of one or more of the fuel gas control valve 310, the oxygen control valve 312, the air control valve 314, or a combination thereof, which can control the burner heat output of the burner 302.

[0141] Referring here to Figures 4 and 5, the molding tool position of the molding tool 324 within the molding station 204 may include the vertical position of the molding tool 324 relative to the glass tube 102 (e.g., in the + / -Z direction of the coordinate axes in Figures 4 and 5), the horizontal position (e.g., in the XY plane of the coordinate axes in Figures 4 and 5), or a combination thereof, controlled by the outer molding tool actuator 326, the inner molding tool actuator 328, or a combination thereof. The horizontal positioning of the molding tool 324 may refer to the horizontal position of the molding tool 324 in the engagement position. When in the engagement position, the horizontal positioning of the molding tool 324 may determine the pressure of the molding tool 324 against the glass tube 102. The timing of contact between the molding tool 324 and the glass tube 102 may be controlled by controlling the operating behavior of the molding tool actuator 326 to adjust the timing of moving the molding tool 324 to engage with and disengage from the glass tube 102 within the molding station 204. As previously discussed, the contact timing can be adjusted to control the total contact time, contact sequence, or both within the molding station 204.

[0142] Referring here to Figure 6, the process setting may be the position of the mechanical stopper 330 within the pipe length drop station 220 or within the forming station 204, the position of which is controlled by the stopper positioning device 332. Other process settings relating to the separation station 206, cooling station 210, drilling station 212, bottom forming station, polishing station, pipe loading station, or other processing stations may also be considered in terms of shifts in attribute distribution.

[0143] In embodiments, shifting the attribute distribution may involve modifying a single process setting. For example, in embodiments, the attribute may be the vial height of a glass vial, and the process setting may be the position of a mechanical stopper 330 in the tube length drop station 220 or forming station 204 of the converter 100. In this case, only one process setting is required to shift the attribute distribution. In embodiments, shifting the attribute distribution may involve changing multiple process settings. For example, in embodiments, the glass article may be a glass vial, the attribute may be the inner diameter of the flange 144 of the glass vial 141, and multiple process settings affect the inner diameter of the flange 144. In the embodiment, process settings for shifting the attribute distribution related to the inner diameter of the flange 144 may include, but are not limited to, the vertical position of the inner forming tool, the horizontal position of the inner forming tool, the vertical position of the outer forming tool, the horizontal position of the outer forming tool, the contact time between the forming tool and the glass tube, the contact sequence between the forming tool and the glass article, the rotational speed of the holder, the heating rate of the heating element in the heating station upstream of the forming station, or other process settings.

[0144] Control relationships may be developed from first principles or empirically using statistical methods. In embodiments, control relationships between attributes and process settings or multiple process settings may be developed through the design of experimental processes. Further information relating to the development of converter control relationships can be found in the concurrently pending U.S. Patent Application No. 17 / 746,396, filed on 17 May 2022 and titled "CONVERTER SYSTEMS AND METHODS FOR CONTROLLING OPERATION OF GLASS TUBE CONVERTING PROCESSES," the full contents of which are incorporated herein by reference.

[0145] Once the updated setpoint for each process setting is determined from the control relationship, the methods disclosed herein may include changing each process setting to its updated setpoint. In embodiments, system 400 may be automatic, and control system 402 may automatically change the process settings to the updated process settings. Referring to Figure 11, in embodiments, system 400 may be partially automatic, and updating the process settings to the updated setpoint may include displaying the updated setpoint for the process settings on the display 430 of control system 402. In response to the display of the updated setpoint for the process settings, the operator may manually change the process settings to the updated setpoint, or use control system 402 to change the process settings to the updated setpoint through a user interface device such as a graphical user interface 432 or other user input device.

[0146] In some embodiments, the control relationship between process settings and attributes may be well-established empirically. In such cases, if the control device is under automatic control, the shift can be directly applied by the control system 402 based on the updated setpoint of the process settings calculated from the control relationship. In situations where there is uncertainty in the control relationship, such as an empirical control relationship that considers and incorporates multiple process settings, the shift can be discounted by a coefficient. In other words, the updated setpoint of the process settings can be modified so that the amount of change in the process settings is reduced in order to mitigate undesirable control responses such as overshoot, vibration, or runaway process control. The coefficient can be developed based on simulation, trial and error, operator intuition and experience, or other considerations. This strategy of discounting the shift by a coefficient may be equivalent to adjusting the integral control algorithm.

[0147] Following the change in process settings to the updated setpoint, the methods disclosed herein may further include verifying the shift in the attribute distribution within the specification range. Verifying the shift in the attribute distribution within the specification range may include measuring attribute values ​​across a lookback window containing a sufficient number of glass articles to produce an attribute distribution that approximates the true distribution of measured attributes, preparing a shifted attribute distribution from the measurements, and comparing the shifted attribute distribution with a predicted attribute distribution. The predicted attribute distribution is the attribute distribution expected from applying the shift and may be the attribute distribution corresponding to the best simulation. In embodiments, the predicted attribute distribution may be calculated by applying the shift to an initial attribute distribution developed from attribute measurements before changing the process settings. The shift is maintained if the shifted attribute distribution and the predicted attribute distribution match. The shifted attribute distribution and the predicted attribute distribution may be considered to match if the yield percentages resulting from each are less than or equal to 1%, less than or equal to 0.5%, or even less than or equal to 0.1%. If the shifted attribute distribution deviates from the predicted attribute distribution, the difference can be further compensated by additional control actions. Whether to take additional action in response to the difference between the predicted attribute distribution and the shifted attribute distribution may depend on a balance of various factors, such as, but are not limited to, the level of automated control or the costs and benefits of making additional changes.

[0148] In embodiments, the difference between the shifted attribute distribution and the predicted attribute distribution can be corrected by providing feedback control to adjust the process settings until the shifted attribute distribution matches the predicted attribute distribution. In embodiments, the method disclosed herein may include: measuring the attributes of a glass article after adjusting the process settings; developing a shifted attribute distribution based on the measured attributes of the glass article after adjusting the process settings; comparing the second attribute distribution with a predicted attribute distribution, the predicted attribute distribution being calculated by applying a shift to the initial attribute distribution; and further adjusting the process settings based on the comparison between the shifted attribute distribution and the predicted attribute distribution. In embodiments, the process of measuring attributes, generating a shifted attribute distribution, comparing the shifted attribute distribution with a predicted attribute distribution, and adjusting the process settings may be repeated multiple times until the shifted attribute distribution matches the predicted attribute distribution. In the embodiment, comparing the shifted attribute distribution with the predicted attribute distribution may include determining the statistical properties of the shifted attribute distribution and the predicted attribute distribution, calculating the error between the statistical properties of the shifted attribute distribution and the statistical properties of the predicted attribute distribution, and shifting the shifted attribute distribution based on the calculated error. In the embodiment, shifting the shifted attribute distribution based on the error may include calculating adjustments to the process settings from the calculated error.

[0149] In some cases, the difference between the post-shift attribute distribution and the predicted attribute distribution may result from discounting the process settings by a coefficient to reduce undesirable control responses (e.g., incrementally adjusting the process settings to the updated process settings to avoid control responses such as overshoot, oscillation, divergent instability, or other undesirable control responses). In other cases, the difference between the post-shift attribute distribution and the predicted attribute distribution may result from changes in the relationship between the process settings and the measured attributes, such as a gradual drift of the process settings over time (e.g., drift resulting from wear) or a stepwise change in the relationship between the process settings and the measured attributes (e.g., resulting from component replacement or other maintenance activities, changes in the inflow fuel gas composition, changes in the ambient environment, etc.).

[0150] When a gradual or abrupt change occurs in the relationship between process settings and measured attributes, the control relationships used to determine process settings for achieving a particular shift in the attribute distribution may not be accurate. In embodiments, the methods herein may include developing updated control relationships between at least one process setting and an attribute. Developing updated control relationships may include calculating updated control relationships based on first principles (e.g., scientific principles, mathematical principles, etc.) or empirically using statistical methods or experimental process designs. Further information relating to designing experimental analyses for developing control relationships for converters can be found in concurrently continuing U.S. Patent Application No. 17 / 746,396, which has been previously incorporated herein by reference. In embodiments, developing updated control relationships may include calibrating one or more control devices of the converter.

[0151] The control strategies of the methods herein can be applied to the entire attribute distribution. In addition to or instead of this, greater refinement in control can be achieved by compensating for known causes of anomalies in the attribute distribution. In some cases, the causes of specific deviations in measured attributes from glass article to glass article may be known with a high degree of certainty, such as in the case of variations between chucks. In these embodiments, the control response may be adjusted to take into account known causes of deviations in measured attributes of glass articles. In embodiments, adjusting at least one process setting may include determining one or more causes of deviations in the attribute distribution outside the specification range and, depending on one or more causes of deviations in the attribute distribution, adjusting the adjustment to the setpoint of at least one process setting control variable.

[0152] For example, known deviations in measurement attributes may arise from differences between each of several holders, and from differences between the chucks incorporated therein that are used to hold and rotate the glass tube during conversion. Greater refinement of the control response can be achieved, but is not limited to, by creating separate controllers as a function of the causes of deviations in measurement attributes, such as vial height. For example, in embodiments, after separating the glass article from the processed end of the glass tube, a particular secondary holder 132 (e.g., the holder and corresponding chuck of the secondary circuit 118 of the secondary processing station 112, see Figure 2) may be known to cause a large percentage of overall variation in the total height of the glass article (e.g., the vial height of a glass vial). In these embodiments, separate control decisions may be applied to the process setting depending on the secondary holder 132 processing the glass article. Specifically, separate attribute distributions may be developed for each holder 130, and these separate attribute distributions may be used to develop a control response for each of the holders 130. The specific secondary holder 132 of each glass article can be tracked using the part tracking system discussed earlier herein. The part tracking system, with its unique identifier and relational database, can track the holder 130 and secondary holder 132 used to produce each glass article 103, and this information can be associated with the measured attributes of the glass article. In this way, the controller can, in some cases, be divided by assignable causes, thereby achieving tighter overall height control. For glass articles that are glass vials, variations in the measured vial flange inner diameter may also be attributable in part to a specific holder 130 in the main circuit 116 of the converter. Therefore, with respect to the flange inner diameter of a glass vial, greater refinement can be achieved by adjusting the control response based on the holder 130 in the main circuit 116 used to produce the glass vial. Other measured attributes may also experience variations between holders.

[0153] In embodiments, the converter comprises a plurality of holders, and operating the converter may include fixing glass tubes to two or more of the plurality of holders and sequentially translating each of the plurality of holders through a plurality of processing stations. Methods disclosed herein may include developing attribute distributions for each of the plurality of holders from attribute measurements and shifting the attribute distributions for each of the plurality of holders within the attribute specification range, wherein shifting the attribute distributions for each of the plurality of holders increases the yield of glass articles. The attribute distributions for each of the plurality of holders may be holder-specific attribute distributions and may be developed from attribute measurements from glass articles associated with a particular holder via a part tracking system. In embodiments, shifting the attribute distributions for each of the plurality of holders may include determining an updated process setting or a set of updated process settings for each of holder 130, secondary holder 132, or both. When each holder 130 or secondary holder 132 is translated to a particular processing station 106, the process settings are changed to an updated process setting or a set of updated process settings for that particular holder 130 or secondary holder 132. The updated process settings for each holder 130, secondary holder 132, or both can be determined from the shift in the attribute distribution and the control relationships for each particular holder 130, secondary holder 132, or both. In embodiments, the control relationships can be developed for each of the individual holders, secondary holders, or both.

[0154] In embodiments, the glass article may be a glass vial, and the attribute may be the overall vial height. During operation, flange, neck, and shoulder features are formed at the processed end of the glass tube through the operation of one or more processing stations of the converter. Following flange formation, the glass tube may be dropped in a tube length drop operation, which may be part of a forming station as previously considered, or incorporated into a separate tube length drop station. After the tube drop operation, the glass tube is heated and separated at a distance from the processed end of the glass tube to produce a partially finished glass article, which is then transferred to a secondary circuit for bottom forming and polishing. The glass vial is then removed from the converter and may be annealed. The method may include measuring the overall vial height of the glass vial. The overall vial height may be measured on the converter after annealing the glass vial, before annealing the glass vial, or after bottom forming. Each measurement may be attributable to a particular glass vial and the specific holder and secondary holder used to produce each particular glass vial. The method may include developing the overall vial height distribution for each of the holders, secondary holders, or both. The method may further include shifting the overall vial height distribution for each of the individual holders, secondary holders, or both by determining the updated process settings for each individual holder or secondary holder from the attribute distribution and shifts in the control relationships for each individual holder or secondary holder. In the case of tube length drop operation, the relationship between vial height and the position of the mechanical stopper may be approximately 1:1.

[0155] In the embodiment, the glass article may be a glass vial, and the measurement attribute may be the inner flange diameter of the glass vial. For the inner flange diameter, process settings may include the inner forming tool position, outer forming tool position, forming tool contact time, forming tool contact sequence, preheat duration, glass temperature, other process settings affecting the inner flange diameter, or a combination thereof. In some cases, the inner flange diameter may be affected by several different process settings.

[0156] In embodiments, the methods disclosed herein for controlling the conversion process may be repeated throughout the operation of the converter. The time frame between iterations of the control method disclosed herein may be sufficient to generate a shifted attribute distribution due to previous changes in the updated process settings, as recognized by the measuring device used to measure the attributes. The time frame between iterations of the control method may depend on the location of the measuring device relative to the location of the process settings controlled by the method. For example, if the measuring device 360 ​​is located downstream of the annealing process, it may take up to 30 minutes for the glass articles to traverse the production line from the processing station where the process settings are located to the measuring device. Once changes in the attribute distribution become apparent at the measuring device 360, the control method may be repeated, in this case beginning with measuring the attributes of a sufficient number of glass articles to generate an attribute distribution that represents the true distribution of the measured attributes. In embodiments, the control system may be configured not to allow any adjustments to the process settings after a predetermined period, which may include the time frame for the glass articles to traverse the production line from the processing station having the process settings to the measuring device, the time required to measure the attributes of a sufficient number of glass articles to obtain a representative distribution, or both. Not allowing changes to the process settings during these times may provide system dynamics time for the process settings to manifest in the finished glass article before any further control response can be developed.

[0157] In any of the methods disclosed herein, the converter 100 may include a plurality of holders 130, and the methods disclosed herein may include fixing one of a plurality of glass tubes 102 to each of the plurality of holders 130, and passing each of the plurality of holders 130 and the glass tubes 102 disposed therein through a plurality of processing stations 106. In any of the methods disclosed herein, each of the plurality of processing stations 106 of the converter 100 may be in a fixed position, and the method may include continuously indexing the glass tubes 102 through each of the processing stations 106. Alternatively, in embodiments, in any of the methods disclosed herein, the converter 100 may be a continuous converter, and the method may include continuously passing the glass tubes through a plurality of processing stations 106, each of the plurality of processing stations 106 may move in coordination with the translation of the glass tubes 102 during the active time.

[0158] Referring again to Figure 11, in an embodiment, the system 400 may include a converter 100 and a distributed computing environment comprising a control system 402, a network 410, and one or more external computing devices 420. The control system 402 may communicate with the external computing devices 420 via the network 410. One or more steps of the methods disclosed herein may be accomplished by using the external computing devices 420 alone or in combination with the control system 402. Although shown in Figure 11 as being directly and communicatively coupled to the converter 100, it is understood that the control system 402 may additionally communicate with the converter 100 via the network 410. The network 410 may be a wired or wireless network. In an embodiment, the network 410 may be a cloud network. The network may be any other type of network, such as a LAN or WAN, but is not limited to these.

[0159] Embodiments of the present disclosure may be embodied in hardware and / or software (including firmware, resident software, microcode, etc.). The control system 402 of the converter 100 and / or other controllers on the converter 100 may include at least one processor and a computer-readable storage medium (i.e., a memory module), as described earlier herein. The control system 402 may be communicably coupled to one or more system components (e.g., the converter 100, the heating element positioning device 318, the burner control valve, the oxygen control valve 312, the air control valve 314, the molding tool actuators 326, 328, the stopper positioning device 332, the chuck 334, the measuring device 360, the converter drive system, etc.) via any wired or wireless communication path. The computer-readable or computer-compatible storage medium or memory module 406 may be any medium on which a program for use by or in connection with an instruction execution system, apparatus, or device may be contained, stored, communicated, propagated, or transported.

[0160] The computer-usable or computer-readable storage medium or memory module 406 may be, for example, an electronic, magnetic, optical, electromagnetic, infrared, or semiconductor system, apparatus, device, or propagation medium, but is not limited to these. More specific examples (a non-exhaustive list) of the computer-readable storage medium or memory module 406 may include an electrical connection with one or more wires, a portable computer diskette, random access memory (RAM), read-only memory (ROM), erasable and programmable read-only memory (EPROM or flash memory), optical fiber, and portable compact disk read-only memory (CD-ROM). It should be noted that the computer-usable or computer-readable storage medium or memory module 406 may, by extension, be paper or another suitable medium on which a program is printed, because a program can be electronically captured, for example, via optical scanning of paper or other medium, and then, if necessary, compiled, interpreted, or otherwise processed in a suitable format, and then recorded in computer memory.

[0161] A computer-readable storage medium or memory module 406 may include machine-readable and executable instructions 408 for performing the operations of the Disclosure. Any of the method steps in this Specification may be performed through the execution of machine-readable and executable instructions 408 by the processor 404 of the control system 402. The machine-readable and executable instructions 408 may include computer program code that can be written in a high-level programming language such as C or C++ for convenience of development. In addition, the computer program code for performing the operations of the Disclosure may also be written in other interpretable languages, etc., but is not limited to these. Some modules or routines may be written in assembly language or even microcode to improve performance and / or memory usage. However, the software embodiments of the Disclosure are independent of implementation in a particular programming language. It will be further understood that any or all of the functions of the program modules may also be implemented using separate hardware components, one or more application-specific integrated circuits (ASICs), or programmed digital signal processors or microcontrollers. [Examples]

[0162] The following examples illustrate the operation of the disclosed system and method for producing multiple glass articles from a glass tube in a converter. The following examples are not intended to limit the scope of the disclosure.

[0163] Vial height control using the control system in Example 1 The following Example 1 illustrates the operation of a vial height control system utilizing the control method disclosed herein to control the vial height of a glass vial. In Example 1, a glass tube was converted into a glass vial using a converter. The converter used was a Vial Forming Machine Model RP18 with an automatic tube feeder manufactured by AMBEG Dr.J.Dichter GmbH, which included 18 processing stations in its main circuit. The converter included a tube drop station with a mechanical stopper and stopper positioning device for repositioning the glass tube so that the separation of the glass vial from the glass tube and bottom finishing resulted in the final vial height of the glass vial. The adjustment to the stopper positioning device for adjusting the position of the mechanical distiller was calibrated so that the change in the position of the mechanical stopper correlated one-to-one with the change resulting in the final vial height of the glass vial.

[0164] After being removed from the converter, the glass vials were annealed. The final vial height attribute was measured after the annealing process. The time between the tube drop station and the measurement of the final vial height after annealing was approximately 30 minutes. During the converter's operation, several glass vials were measured for their final vial height. The measured final vial heights were then used to generate an attribute distribution of the final vial height. The attribute distribution was compared to the specification limits of the final vial height (e.g., lower specification limit 1302 and upper specification limit 1304 in Figure 13). Shifts in the attribute distribution were determined to maximize yield by developing multiple shift simulations. The process setting, which is the position of the mechanical stopper, was determined using the best simulation and the control relationship between the final vial height and the position of the mechanical stopper (i.e., a 1:1 relationship between vial height and stopper position). For Example 1, the change in the position of the mechanical stopper was discounted by 50% for robustness. The 50% discount is arbitrarily selected and allows the control response to be better illustrated.

[0165] Referring to Figure 3, the data for Example 1, including the relative final vial height as a function of time, is graphically depicted. As described above, the control system for controlling vial height required appropriate adjustment to the final vial height in order to increase yield. As shown in Figure 3, after the adjustment, a 30-minute waiting period was experienced until glass vials molded under the updated process settings began to reach the measurement system. Thus, in addition to the 30-minute delay, the time required to measure a sufficient number of glass vials was established during the adjustment to the stopper positioning device.

[0166] In Figure 13, the data shows frequent start-ups and shutdowns of the converter, which were due to testing and troubleshooting unrelated to the operation of the vial height control system. Despite the start-ups and shutdowns, Figure 13 clearly shows that the vial height control system, based on attribute distribution shifts, succeeded in adjusting the final vial height within the specification range to maximize yield and maintaining the final vial height within the specification range. Therefore, Figure 13 shows that the control method disclosed herein is effective in controlling the final vial height of glass vials to provide a higher yield.

[0167] Flange inner diameter control using the control system in Example 2 In Example 2, a flange diameter control system utilizing the control method disclosed herein was implemented to control the flange diameter of glass vials. In Example 2, the glass vials were produced using the converter of Example 1. After exiting the converter, the glass vials were annealed, and the flange diameter was measured using a measuring device positioned downstream of the annealing process. The flange diameter control system of Example 2 included a manual user in the control loop. Specifically, the flange diameter control system of Example 2 was configured to measure the flange diameters of multiple glass vials, generate an attribute distribution from the flange diameter measurements, determine a shift in the attribute distribution that yields the maximum yield, and determine an updated process setting corresponding to the shift in the attribute distribution. The flange diameter control system of Example 2 was further operable to display the attribute distribution, the proposed shift in the attribute distribution, and the proposed updated process setting on a display. The manual user then observed the adjustment to the process setting, and subsequently the manual user executed the change to the process setting on the converter.

[0168] Regarding the flange inner diameter, the process settings affecting the flange inner diameter relate to the addition or removal of glass to the forming station for forming the flange. The addition or removal of glass to the forming station is directly related to the servo-adjusted height of the forming station relative to the processed end of the glass tube. Specifically, the process settings include the position of one or more of the forming tool positioning devices within the forming station, which control the vertical position (e.g., height) of the forming tool within the forming station relative to the processed end of the glass tube. Referring to Figure 14, the flange inner diameter has a lower specification limit 1402 and an upper specification limit 1404. The flange inner diameter is required to have a maximum inner diameter measurement and a minimum inner diameter measurement between the lower specification limit 1402 and the upper specification limit 1404.

[0169] Referring again to Figure 14, the trace of the measured flange inner diameter is graphically depicted. The trace in Figure 14 includes the maximum flange inner diameter, minimum inner diameter, and average inner diameter for each of the multiple glass vials measured. Now referring to Figure 15, the average position of the forming tool relative to the processed end of the glass tube is graphically depicted in box plot form as a function of the number of holders in the main circuit. Figure 16 shows the yield percentage by the number of holders in the main circuit. As shown in Figures 14 and 15, the distribution center of the flange inner diameter correlates well with the number of holders in the main circuit because any error or variation in the position of each holder is also an error in the position of the burner and forming tool relative to the processed end of the glass tube in each processing station. Figures 14 and 15 may be displayed on a screen and can be used to identify outlier holders that may require maintenance such as servicing or adjustment. Knowing the variation between holders can be used to bring about different adjustments to the process settings for each holder.

[0170] Referring to Figure 17, the actual historical yield 1702 as a function of time (x-axis), along with the predicted yield 1704 that can be achieved by adjusting the process settings in response to shifts in the attribute distribution, are graphically depicted for Example 2. As shown in Figure 17, without adjustment, the actual historical yield 1702 decreases over time. The predicted yield 1704 shows that by adjusting the process settings based on shifts in the attribute distribution, the yield of glass vials relative to the flange inner diameter can be increased to 100% or close to it.

[0171] The control system was configured to provide and display recommended adjustments to the process settings (i.e., the position of the forming tool relative to the processed end of the glass tube) to increase yield. Referring here to Figure 18, for Example 2, the history of recommended adjustments to the process settings is graphically plotted as a function of time. Based on the data in Figure 18, the control system recommended adjusting the position of the forming tool in the forming station to approximately 120 μm. As shown in Figure 18, the recommendations for adjustments to the process settings are fairly consistent, ranging from approximately -105 μm to approximately -140 μm over one hour of converter operation time. It should be noted that even if the yield is 100%, recommended adjustments may still exist because, if 100% is achievable, the best attribute shift will maximize the amount of shift that may occur before the yield begins to fall below 100%. This improves the process robustness against further future changes or drifts in attribute measurements.

[0172] Examples 3-16 In Examples 3–16, the control strategy described in Example 2 was used to manually adjust the molding tool position for 14 different operating time tests across six different converter production lines for producing glass vials. Measurement of the flange inner diameter, development of the attribute distribution, determination of the best attribute shift to increase yield, and calculation of the updated process settings to achieve the shift in the attribute distribution were performed by the control system as described in Example 2 and then displayed on the screen. For each of Examples 3–16, the updated process settings were implemented by a human operator. Note that adjustments were made only when the control system indicated an opportunity for yield improvement by shifting the attribute distribution. The yield of glass vials relative to the flange inner diameter was determined one hour before and one hour after the change in the process settings. Referring now to Figure 19, the yields one hour before and one hour after the change in the process settings for each of Examples 3–16 are graphically depicted. For each of Examples 3 to 16 in Figure 19, the bar on the left represents the yield one hour before the process setting change, and the bar on the right represents the yield one hour after the process setting change. Reference number 1902 represents a yield of 100%. On average for Examples 3 to 16, the yield improvement rate resulting from the change in process settings was 4.8%.

[0173] Various embodiments of converters and systems for producing multiple glass articles from a glass tube, and methods for providing feedback control of the converter, are described herein, but it should be understood that each of these embodiments and techniques may be used individually or in combination with one or more embodiments and techniques.

[0174] Those skilled in the art will see 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 encompass various modifications and variations to the embodiments described herein, insofar as such modifications and variations fall within the scope of the appended claims and their equivalents.

Claims

1. A method for controlling a converter for producing glass articles from glass tubes, the method being: Operating the converter to produce the glass article from the glass tube, wherein the converter comprises a plurality of processing stations, and operating the converter includes continuously translating the glass tube through each of the plurality of processing stations. Measuring the attributes of the glass article during or after conversion, wherein the attributes undergo gradual changes over time, sudden changes, or both, and the measurement is performed accordingly. Develop an attribute distribution from the measured values ​​of the aforementioned attributes, A method comprising shifting the attribute distribution within the specified range of the attribute, wherein shifting the attribute distribution increases the yield of the glass article.

2. The method according to claim 1, wherein shifting the attribute distribution includes adjusting at least one process setting.

3. The method according to claim 2, wherein adjusting the at least one process setting includes determining an updated setpoint for the at least one process setting and adjusting the at least one process setting to the updated setpoint.

4. Determining the updated setting point of the at least one process setting is: To determine the shift in the attribute distribution within the specification range that increases the yield of the glass article, The method according to claim 3, comprising calculating the updated setting point of the at least one process setting from the magnitude and direction of the shift in the attribute distribution and the control relationship between the at least one process setting and the attribute.

5. Determining the shift in the attribute distribution within the specification range that increases the yield of the glass article is: Performing multiple simulations, wherein in each of the multiple simulations, the attribute distribution is shifted by different magnitudes, directions, or both. The process involves determining the best simulation from the aforementioned multiple simulations, wherein the best simulation is the one that produces the maximum yield of the glass article. The method according to claim 4, comprising setting the magnitude and direction of the shift in the attribute distribution to be equal to the magnitude and direction corresponding to the best simulation.

6. The method according to claim 5, wherein two or more of the aforementioned simulations result in a 100% yield of the glass article, and the best simulation is the one in which the minimum absolute value of the difference between the measured value of the attribute distribution and the upper or lower limit of the specification range is the maximum, and the yield of the glass article is 100%.

7. Two or more of the aforementioned simulations resulted in a 100% yield of glass articles. The aforementioned attribute is known to drift toward the upper or lower limit of the specification range. The method according to claim 5, wherein the best simulation includes a simulation that yields 100% of the glass article and provides the maximum absolute difference between either the upper or lower limit and the measurement closest to either the upper or lower limit, respectively.

8. Determining the shift in the attribute distribution within the specified range means that To determine whether the advantages of shifting the attribute distribution within the specified range outweigh the costs of shifting the attribute distribution, If the benefits of shifting the attribute distribution outweigh the costs, adjust at least one process setting to shift the attribute distribution within the specified range. The method according to claim 5, comprising maintaining the at least one process setting if the benefit of shifting the attribute distribution is less than the cost.

9. Determining the shift in the attribute distribution within the specification range that increases the yield of the glass article is: The attribute distribution is analyzed to determine the characteristics, relationships, or both of the attributes that make up the attribute distribution. The method according to claim 4, comprising calculating the shift in the attribute distribution within the specification range that increases the yield of the glass article, based on the characteristics, relationships, or both of the attribute distribution.

10. The method according to claim 9, wherein analyzing the attribute distribution and determining the characteristics, relationships, or both of the attribute distribution is a feature of the attribute distribution, and further comprising applying a first principle, a statistical method, or both to the attribute distribution.

11. After adjusting at least one of the process settings, the attributes of the glass article are measured, After adjusting at least one of the process settings, a shifted attribute distribution is developed based on the measured attributes of the glass article. The comparison involves comparing the shifted attribute distribution with a predicted attribute distribution, the predicted attribute distribution being calculated by applying the shift to the attribute distribution that occurred before adjusting at least one process setting. The method according to claim 4, further comprising adjusting the at least one process setting based on the comparison between the shifted attribute distribution and the predicted attribute distribution.

12. The method according to claim 11, wherein comparing the shifted attribute distribution with the predicted attribute distribution includes calculating an error between the same characteristics of the shifted attribute distribution and the predicted attribute distribution, and shifting the shifted attribute distribution is based on the error.

13. The method according to claim 11, comprising developing an updated control relationship between the at least one process setting and the attribute.

14. The method according to claim 13, wherein developing the updated control relationship includes designing an experimental process or calibration.

15. Adjusting at least one of the aforementioned process settings is To determine one or more causes of the deviation in the attribute distribution outside the specified range, The method of claim 2, comprising: modifying the adjustment of the at least one process setting to the setting point in accordance with one or more causes of the deviation of the attribute distribution.

16. The converter comprises multiple holders, Operating the aforementioned converter means The glass tube is fixed to two or more of the aforementioned holders, This includes translating each of the plurality of holders in succession through the plurality of processing stations, The method described above is For each of the aforementioned holders, an attribute distribution is developed from the measured values ​​of the attribute, The method according to claim 1, further comprising shifting the attribute distribution for each of the plurality of holders within the specification range of the attribute, wherein shifting the attribute distribution for each of the plurality of holders increases the yield of the glass article.

17. Shifting the attribute distribution within the specified range means To determine whether a shift in the attribute distribution within the specified range of the attribute increases the yield of the glass article, The method according to claim 1, comprising shifting the attribute distribution within the specified range for the attribute if the shift in the attribute distribution increases the yield of the glass article.

18. If the shift in the attribute distribution does not increase the yield, the method further comprises maintaining the at least one process setting at the current setpoint.

19. The method according to claim 1, wherein the glass article is a glass vial, and the attributes are selected from vial height and the inner diameter of the flange, the outer diameter of the flange, the thickness of the flange, the height of the flange, the radius of the shoulder, the height of the shoulder, the outer diameter of the neck, or a combination thereof.

20. The method according to claim 19, wherein the attribute is the vial height of the glass vial.

21. The method according to claim 20, wherein the at least one process setting is the stopper height in the tube drop station of the converter.

22. The method according to claim 19, wherein the glass article is a glass vial, and the attribute is the inner diameter of the flange of the glass vial.

23. The method according to claim 1, wherein developing the attribute distribution includes measuring the attribute across a lookback window.

24. The method according to claim 23, wherein the lookback window comprises a statistically related number of produced glass articles.

25. The method according to claim 1, further comprising measuring the attributes of the glass article after forming one or more characteristic parts of the glass article at the processed end of the glass tube.

26. Operating the converter involves forming one or more characteristic parts of the glass article at the processed end of the glass tube, and after forming, separating the glass article from the processed end of the glass tube. The method according to claim 1, comprising: molding one or more characteristic parts of the glass article; separating the glass article from the processed end of the glass tube; and then measuring the attributes.

27. The method according to claim 1, comprising measuring the attributes of the glass article after conversion for production.

28. The method according to claim 27, further comprising operating the converter to produce the glass article from the glass tube, and then annealing the glass article, wherein the measurement of the attributes is performed after the glass article has been annealed.

29. The method according to claim 1, wherein the attribute distribution deviates from a normal distribution or is an asymmetric distribution.

30. A system for producing glass articles from glass tubes, wherein the system is A converter comprising multiple processing stations and at least one control device, The converter is capable of sequentially translating the glass tube through each of the processing stations, Translating the glass tube sequentially through each of the processing stations forms one or more characteristic parts of the glass article and separates the glass article from the processed end of the glass tube. The glass article includes attributes, The at least one control device includes a converter that is operable to change process settings affecting the attributes of the glass article, A measuring device positioned to measure the attributes of the glass article during or after conversion, A control system communicatively coupled to the converter and the measuring device, the control system comprising a processor, a memory module communicatively coupled to the processor, and machine-readable and executable instructions stored in the memory module, wherein the machine-readable and executable instructions are automatically communicated to the control system when executed by the processor. Using the aforementioned measuring device, the attributes of the glass article are measured. Based on the measured values ​​of the attributes of the glass article, an attribute distribution is developed. Determine whether a shift in the attribute distribution within the specified range of the attribute increases the yield of the glass article. A system comprising: a control system that shifts the attribute distribution within the specified range of the attribute if the shift in the attribute distribution increases the yield of the glass article.

31. The system according to claim 30, wherein the measuring device is positioned within the processing station of the converter, coupled to one or more holders of the converter, positioned downstream of the converter, or a combination thereof.

32. The system according to claim 30, wherein the system includes an annealing process for annealing the glass article, and the measuring device is positioned downstream of the annealing process.

33. The plurality of processing stations include a pipe length drop station equipped with a mechanical stopper and a stopper actuator, The stopper actuator is configured to change the position of the mechanical stopper in the axial direction with respect to the processed end of the glass tube. The system according to claim 30, wherein the attribute is the overall height of the glass article.

34. The glass article is a glass vial, The plurality of processing stations include at least one flange forming station, which includes one or more forming tools and one or more forming tool actuators that are operable to change the position of one or more forming tools. The system according to claim 30, wherein the attribute is the inner diameter of the flange of the glass vial.

35. The system according to claim 30, wherein when the machine-readable and executable instructions are executed by the processor, the control system automatically adjusts at least one process setting of the converter to shift the attribute distribution within the specified range for the attribute.

36. The machine-readable and executable instructions are automatically provided to the control system when executed by the processor. If the shift in the attribute distribution increases the yield of the glass article, determine the updated setpoint of the at least one process setting. The system according to claim 35, wherein the at least one process setting is adjusted to the updated setting point.

37. The system according to claim 36, wherein, when the machine-readable and executable instructions are executed by the processor, the control system causes the control system to automatically calculate the updated setpoint of the at least one process setting from the magnitude and direction of the shift in the attribute distribution, and the control relationship between the at least one process setting and the attribute.

38. When the machine-readable and executable instructions are executed by the processor, the control system automatically... Performing multiple simulations, wherein in each of the multiple simulations, the attribute distribution is shifted by different magnitudes, directions, or both. The process involves determining the best simulation from the aforementioned multiple simulations, wherein the best simulation is the one that produces the maximum yield of the glass article. The system according to claim 37, which causes the magnitude and direction of the shift within the attribute distribution to be set to be equal to the magnitude and direction corresponding to the best simulation.

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