Blow Molding Heater Control for Preform Temperature Stability
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Solution Overview
Problem
Existing blow molding apparatuses face challenges in quickly adjusting the temperature of preforms and the air inside the heating device to the optimum level, leading to discarded preforms when the apparatus is stopped or restarted, which affects productivity and efficiency.
Innovation Solution
A control method and device that adjust the heating and cooling performance of the heating device based on real-time temperature measurements, allowing for rapid temperature adjustment of preforms and air to the optimum level, using a control device with a processor to manage heater and blower outputs and extend the molding cycle as needed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the heater and blower are used to raise and adjust the air temperature inside the heating device, then the air temperature reaches the predetermined temperature, but it takes a relatively long time
Solution Approach 1:
The control device performs preliminary heating of the air inside the heating device when the blow molding apparatus is stopped temporarily. By activating the heater and blower during the stop period, the system prepares the optimal temperature environment in advance, so that when production resumes, the preforms can be immediately heated without delay. This preliminary action eliminates the temperature adjustment delay that would otherwise occur at the resumption point.
Solution Approach 2:
The heating and air circulation process is made continuous by maintaining heater and blower operation during temporary stops. Instead of shutting down all heating functions, the system continues to circulate and maintain optimal temperature in the heating device, ensuring that the useful heating action never truly stops. This continuity prevents the need for re-heating after stops, maintaining productivity.
2Temperature
If the heater output and ambient temperature are not properly adjusted, then the preform cannot be heated to the optimum temperature, but preforms are discarded as they cannot be blow-molded
Solution Approach 1:
The control device continuously monitors the actual temperature of preforms and the ambient temperature inside the heating device, comparing these values against predetermined optimal ranges. Based on this feedback, the system automatically adjusts the heater output and blower operation to maintain temperatures within the optimal range, ensuring consistent preform quality and preventing discards due to improper heating.
Solution Approach 2:
The system dynamically changes heating parameters (heater output power, air circulation rate) based on real-time temperature measurements and production conditions. By adjusting these parameters to match the actual state of preforms and ambient conditions, the system ensures optimal heating performance and prevents quality defects that would lead to discards.
3Productivity
If the blow molding apparatus is stopped for some reason, then energization to the heating device is also stopped, but the air inside the heating device becomes outside the optimum temperature
Solution Approach 1:
When the blow molding apparatus is stopped temporarily, the control device initiates preliminary heating of the air inside the heating device by activating the heater and blower. This prepares the optimal temperature environment in advance, so that when production resumes, the heating device is already at the required temperature and can immediately process preforms without delay or quality issues.
Solution Approach 2:
The heating device operates dynamically with different power states based on production needs. During temporary stops, the system transitions to a preliminary heating mode with adjusted heater and blower operation, rather than complete shutdown or full continuous operation. This dynamic adjustment optimizes energy use while maintaining temperature readiness.
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
Enables rapid temperature adjustment of preforms and air to the optimum level, reducing the number of discarded preforms and enhancing productivity by ensuring consistent temperature distribution for mass production.
Implementation Method 1
The heating device is configured to heat the preform by using near-infrared (light) radiation heat from a near-infrared heater
Implementation Method 2
convective heat of high-temperature air (atmosphere) inside the heating device
Data Source
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AI summary
Provided is a control method for a manufacturing device for manufacturing a resin container by blow-molding a preform, the method including: a step (S100) for acquiring a target value for the temperature inside a heating device for heating the preform to a temperature that is appropriate for blow-molding; a step (S100) for acquiring the actual measured value of the temperature inside the heating device, the temperature having been detected by a sensor disposed inside the heating device; a step (S120) for calculating the temperature difference between the target value and the actual measured value; and a step (S130) for adjusting the heating performance and the cooling performance of the heating device on the basis of the temperature difference.