Automated Throttle Adjustment for Plastic Preform Forming
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Solution Overview
Problem
Existing plastic container forming devices face challenges in maintaining consistent quality due to manual adjustments of throttle devices during type changes, leading to potential errors and increased downtimes.
Innovation Solution
An automated system for adjusting throttle devices, utilizing a central control and drive mechanisms to automatically change the throttle cross-sections without manual intervention, ensuring accurate settings across all forming stations during process changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual adjustment of throttle devices is used during type changes, then ease of operation is improved, but reliability deteriorates due to potential human error and inconsistent quality
Solution Approach 1:
The system automatically adjusts throttle devices based on pre-stored optimal settings for different container types. The control unit retrieves and applies the correct throttle cross-section automatically during type changes, eliminating the need for manual intervention and ensuring consistent quality without human error.
Solution Approach 2:
Optimal throttle settings for different container types are pre-calculated and stored in the control unit before production. When a type change is detected, the system automatically retrieves the pre-stored settings and applies them immediately, eliminating the need for manual adjustment during the changeover process.
2Device complexity
If manual adjustment of throttle devices is used during type changes, then device complexity is reduced, but loss of time increases due to manual intervention and potential errors
Solution Approach 1:
The control system automatically manages throttle adjustments during type changes without requiring operator intervention. The system detects the type change, retrieves the appropriate settings, and applies them automatically, significantly reducing downtime while the added automation complexity is justified by the productivity gains.
Solution Approach 2:
All throttle settings for different container types are pre-programmed into the control unit. During type changes, the system automatically switches between pre-configured settings, eliminating the time-consuming manual adjustment process and reducing changeover downtime.
3Reliability
If automated throttle adjustment is implemented, then reliability is improved by eliminating human error, but device complexity increases due to automation systems
Solution Approach 1:
The control unit automatically retrieves and applies pre-stored throttle settings based on container type detection. This self-service approach ensures consistent quality by eliminating manual adjustment errors, while the automation complexity is managed through software-based control rather than complex mechanical systems.
Solution Approach 2:
The patent replaces manual mechanical adjustment with an automated control system that uses sensors, processors, and actuators. This substitution increases reliability by eliminating human error, while the complexity is concentrated in the control software rather than the mechanical adjustment mechanism itself.
4Productivity
If automated throttle adjustment is implemented, then productivity is improved by reducing downtime, but device complexity increases due to automation mechanisms
Solution Approach 1:
All throttle settings for different container types are pre-programmed into the control unit before production begins. During type changes, the system automatically retrieves and applies the correct pre-configured settings, enabling rapid changeovers and maximizing productivity without requiring complex real-time calculation or adjustment mechanisms.
Solution Approach 2:
The patent replaces time-consuming manual mechanical adjustment with an automated electronic control system. This substitution reduces changeover downtime and increases productivity, while the complexity is concentrated in the control software and sensors rather than complex mechanical adjustment mechanisms.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution eliminates the risk of human error and reduces downtime by enabling seamless and precise adjustments of throttle devices, ensuring consistent quality in plastic container production across multiple forming stations.
Implementation Method 1
the drive (80) is suitable and intended to rotate the transport carrier (22)
Implementation Method 2
a first compressed air reservoir (32) which is suitable and intended to store and/or provide compressed air under a first predetermined pressure and a second compressed air reservoir (34) which is suitable and intended to store compressed air under a second predetermined pressure
Implementation Method 3
heated plastic preforms are placed into blow molds and expanded into plastic bottles within these molds by exposure to a gaseous medium
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
Device for forming plastic preforms (10) into plastic containers, with a transport device (2) which transports the plastic preforms (10) along a predetermined transport path, wherein the transport device (2) has a transport carrier (22) on which a plurality of forming stations (20) for forming the plastic preforms (10) are located, wherein these forming stations each have supply devices (84) which supply the plastic preforms with a flowable and in particular gaseous medium for their expansion, and wherein the device (1) has at least a first compressed air reservoir (32) which is suitable and intended for storing compressed air at a first predetermined pressure, and a second compressed air reservoir which is suitable and intended forto store compressed air at a second predetermined pressure (p2) and each forming station (20) has a valve arrangement (4) with a plurality of valve devices (52, 54) to apply the at least two pressures to the plastic preforms and wherein the forming stations each have at least one throttling device (6) which is suitable and intended to throttle the volume flow of the gaseous medium to the plastic preforms (10), characterized in that the throttling device (6) is automatically adjustable.