Blow Molder Control Using Energy-Aware Parameter Optimization
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Solution Overview
Problem
Blow molding processes face challenges in efficiently optimizing container production parameters to balance energy efficiency and container quality, as manual adjustments are cumbersome and often result in increased operating costs without compromising container performance.
Innovation Solution
A blow molder controller system that executes a system model to relate input parameter changes to container characteristics, using energy and operating cost data to select parameter adjustments that drive containers towards desired characteristics while minimizing energy consumption and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual adjustments of blow molder parameters are made to optimize container quality, then container characteristics can be improved, but operating costs and energy consumption increase
Solution Approach 1:
The system implements a feedback mechanism where container characteristics are measured by inspection systems and fed back to the controller, which automatically adjusts blow molder parameters to maintain optimal container quality without manual intervention, thereby reducing energy consumption associated with manual optimization processes
Solution Approach 2:
The blow molder controller autonomously optimizes its own operating parameters by receiving feedback from container inspection systems and automatically adjusting parameters through the system model, eliminating the need for external manual adjustments and reducing associated energy costs
2Productivity
If the number of molds in the blow molder is increased to increase product rate, then productivity improves, but the rate of defective containers increases when process problems occur
Solution Approach 1:
Container inspection systems continuously monitor container quality and provide feedback to the controller, which detects process problems early and triggers automatic parameter adjustments to prevent defective containers even when multiple molds are operating at high productivity
Solution Approach 2:
The system model predicts the impact of parameter changes on container characteristics before implementation, allowing the controller to make preliminary adjustments that prevent defective containers from being produced in the first place, thereby maintaining high reliability at increased productivity
3Use of energy by moving object
If automated control systems are implemented to optimize blow molder parameters, then energy efficiency improves, but system complexity increases
Solution Approach 1:
The controller integrates multiple functions including executing the system model, receiving feedback from inspection systems, automatically adjusting parameters, and monitoring energy consumption within a single unified system, reducing overall system complexity while maintaining energy efficiency optimization capabilities
Solution Approach 2:
The system model acts as an intermediary that mathematically relates input parameters to container characteristics, serving as a virtual representation of the blow molding process that simplifies the control logic and reduces the complexity of direct physical control system implementation
Data Source
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AI summary
Blow molder system and associated method optimizes the performance, energy efficiency and/or operating costs of the blow molder. A blow molder controller executes a system model that relates blow molder input parameter changes to the characteristics of containers generated by the blow molder. Equipped with energy and/or operating cost data for operating the blow molder, the blow molder controller can select a set of blow molder input parameter changes for the blow molder that: drives the containers produced by the blow molder toward desired container characteristics, in an efficient amount of time, and in cost effective manner, considering the energy costs involved in implementing the changes.