Blow Molding Machine Initial Setup Using Pre-Recorded Formulas
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Solution Overview
Problem
The existing methods for producing plastic containers by blow molding are time-consuming and require manual adjustment of numerous parameters, often relying on trial and error, which is tedious and operator-dependent, especially when transitioning between different container models and preform models.
Innovation Solution
An automated method for initial adjustment of the forming machine using pre-recorded formulas that calculate adjustment parameters based on preform and container parameters, allowing for independent setup without relying on external databases or installations, thereby simplifying the process and reducing operator expertise requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual trial and error method is used to adjust forming machine parameters, then the forming machine can be adjusted to produce containers conforming to desired models, but the adjustment process becomes time-consuming and requires operator expertise
Solution Approach 1:
The patent applies preliminary action by pre-calculating and storing optimal forming parameters in a database before actual production. When a container model is selected, the system retrieves pre-determined parameters instead of performing trial-and-error adjustments, thus eliminating time loss while maintaining precision.
Solution Approach 2:
The patent introduces a database as an intermediary between the operator and the forming machine parameters. The database stores pre-calculated optimal parameters and provides them automatically, acting as a mediator that eliminates the need for manual trial-and-error adjustment while ensuring precise container formation.
2Manufacturing precision
If trial and error method is used for parameter adjustment, then the forming machine can be calibrated, but the process requires operator expertise and understanding of production facility
Solution Approach 1:
The patent implements self-service by enabling the system to automatically determine and adjust forming parameters without requiring operator intervention or expertise. The control unit automatically retrieves parameters from the database and adjusts the forming machine, making the system self-sufficient and eliminating the need for specialized operator knowledge.
Solution Approach 2:
The database acts as an intermediary that provides pre-calculated optimal parameters automatically, eliminating the need for operators to have deep understanding of production facilities. The system handles all calibration tasks autonomously through this intermediary layer.
3Manufacturing precision
If verification phase is performed after container production, then recipe can be corrected, but the entire installation must be run for calibration and correction is done by trial and error
Solution Approach 1:
The patent applies preliminary action by determining all necessary forming parameters before container production begins. By pre-calculating and setting parameters based on preform and container characteristics, the system eliminates the need for post-production verification and trial-error corrections, thereby maintaining precision while maximizing productivity.
4Adaptability or versatility
If manual adjustment of numerous parameters is performed, then the forming machine can be configured for different container models, but the process becomes tedious and operator-dependent
Solution Approach 1:
The patent applies universality by creating a database that stores optimal parameters for multiple container and preform models. The system can handle different container models by simply retrieving the appropriate pre-stored parameters, providing multi-functionality without requiring manual adjustment for each model, thus maintaining adaptability while simplifying operation.
Solution Approach 2:
The system performs self-service by automatically selecting and applying the correct parameters from the database based on the chosen container and preform models. This eliminates the need for operators to manually adjust numerous parameters for different models, making the process simple and non-tedious while maintaining full adaptability.
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 approach enables rapid and accurate initial adjustment of the forming machine, allowing for the production of containers that conform to desired models with reduced time and operator intervention, improving efficiency and precision in container production.
Implementation Method 1
a preform heating phase, during which a series of preforms are heated to a reference temperature at which they are malleable and can be formed
Implementation Method 2
a pressurized fluid is injected into each preform by the corresponding injection device to give the preform its final container shape
Implementation Method 3
a stretching phase performed by means of a moving rod arranged to apply a stretching force to the bottom of a preform within a mold. This stretches the preform along its axis, helping to keep the preform centered within the mold
Data Source
Figure 1
Figure 2
AI summary
Initial setup method for a production installation (1) of a series of containers (2) of a given container design from a series of plastic preforms (4) of a given preform design, said installation comprising at least one forming machine (16), comprising at least one forming station (54) in which a preform from the series of preforms (4) is formed into a container, the initial setup method comprising the following steps: - determining at least one preform parameter relating to the preform design introduced into the installation and at least one container parameter relating to the container design to be produced from said preform design, - determining at least one setting parameter of the forming machine (16) enabling the production of a container (2) conforming to said container design from a preform (4) conforming to said preform design,- to adjust said forming machine (16) according to said preform, container and adjustment parameters, characterized in that the step of determining at least one adjustment parameter of the forming machine (16) is done by calculation from pre-recorded formulas, said formulas using the preform parameter and the container parameter.