Automated Blow Mold Changing Device for Injection Molding Machines
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Solution Overview
Problem
Existing blow molding machines require lengthy changeover times due to manual replacement of blow molds, which can lead to incorrect mold usage and malfunctions if not properly loaded, resulting in production interruptions and increased inspection times.
Innovation Solution
A method and device that separate the forming device into two protected areas, allowing the changing device to operate independently, enabling partial or fully automatic blow mold replacement with a robot or gripper system that can identify and correctly position blow molds, reducing human error and increasing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If manual replacement of blow molds is used, then the device complexity is reduced, but the changeover time increases and productivity decreases
Solution Approach 1:
The system enables automatic self-service through the robot's autonomous operation. The robot independently identifies blow mold positions using sensors, navigates to forming stations, and performs replacement operations without human intervention, thereby reducing changeover time while maintaining manageable device complexity through automated self-sufficient operation
Solution Approach 2:
Manual mechanical operations are replaced by an automated robot system equipped with sensors and control units. The robot uses optical or RFID sensors for identification, mechanical grippers for handling blow molds, and automated navigation to replace manual replacement processes, significantly improving productivity while the modular design keeps complexity controlled
2Ease of operation
If manual replacement of blow molds is used, then the ease of operation is maintained, but the reliability decreases due to potential incorrect loading
Solution Approach 1:
The system incorporates sensor-based feedback mechanisms that automatically verify blow mold identification and positioning. Optical sensors, RFID readers, or cameras detect blow mold characteristics and confirm correct placement at forming stations, providing real-time feedback to the control unit to prevent incorrect loading and ensure reliable operation
Solution Approach 2:
Manual operations are replaced by an automated robot system with integrated sensors and control logic. The robot autonomously identifies blow molds, navigates to correct positions, and executes replacement operations with precision, eliminating human error while maintaining ease of operation through automated processes
3Productivity
If automatic robot-based blow mold replacement is implemented, then the productivity increases and reliability improves, but the device complexity increases
Solution Approach 1:
The system is divided into modular functional segments: robot navigation module, sensor identification module, gripper handling module, and control unit. Each module performs a specific function independently, allowing the complex automated replacement process to be managed through segmented, manageable components that improve productivity without overwhelming complexity
Solution Approach 2:
The robot system is designed as a universal platform capable of performing multiple functions: navigating to different forming stations, identifying various blow mold types using sensors, handling different mold sizes with adjustable grippers, and coordinating with the control unit. This multi-functionality consolidates multiple operations into a single system, improving productivity while controlling overall device complexity
4Ease of operation
If operator access is allowed during operation, then the ease of operation is maintained, but the safety decreases
Solution Approach 1:
The operating environment is segmented into protected zones separated by physical barriers or interlocked safety systems. The robot operates within designated work cells or enclosed areas, while operators access control panels or monitoring stations outside these zones. This spatial segmentation maintains operational ease through controlled access while eliminating safety hazards from unauthorized entry during automated operations
Data Source
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AI summary
The invention relates to a method for operating a forming device (1) for forming plastic preforms (10) into plastic containers (20), wherein, in a working operation of the device (1), the plastic preforms (10) are transported via a plurality of forming stations (8) and expanded to form the plastic containers (20) by the admission of a fluid medium, wherein blow moulding devices (14) are used to expand the plastic preforms (10), inside which devices the plastic preforms (10) are expanded to form the plastic containers (20). In a changing operation, at least one of the blow moulding devices (14) of the device (1) is removed and/or one of the blow moulding devices (14) is arranged on a blow mould carrier (16) of the device (1), and a changing device (40), which has a gripping device (52) for gripping the blow moulding device (14), is used to change the blow moulding devices (14). According to the invention, in a working operation, the forming device (1) is operated in a first protection region (S1) that cannot be accessed by the machine operator, and the changing device (40) is arranged at least partially in a second protection region (S2) that can be at least periodically accessed by the machine operator during the working operation, wherein a connection can be created between the first protection region (S1) and the second protection region (S2).