Blow Moulding Compressor Control for Energy Reduction
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Solution Overview
Problem
The high operating costs associated with blow molding processes due to the inefficiency in using recycled compressed air, as existing methods do not adequately reduce energy consumption and costs.
Innovation Solution
The integration of a compressor control system with the blow molding machine's control system to optimize energy usage by determining the required output pressure by adding the blowing pressure needed and an additional differential pressure, thereby reducing electrical power consumption and operating costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If a compressor control system is integrated with the blow molding machine's control system to optimize energy usage, then electrical power consumption is reduced, but device complexity increases
Solution Approach 1:
The patent integrates the compressor control system with the blow molding machine's control system by establishing communication between the compressor control and the machine control unit. This merging allows the systems to exchange data and coordinate operations, enabling the compressor to be controlled based on the actual blowing requirements of the machine, thereby reducing energy consumption while maintaining operational efficiency.
Solution Approach 2:
The integrated control system implements feedback mechanisms where the blow molding machine's control unit communicates with the compressor control to provide information about actual blowing pressure requirements. This feedback loop enables the compressor to adjust its output dynamically, avoiding unnecessary energy consumption from maintaining constant high pressure, thus resolving the contradiction between energy efficiency and system complexity.
2Loss of energy
If the compressor generates only the necessary pressure level by adding blowing pressure and differential pressure, then operating costs are reduced, but measurement precision requirements increase
Solution Approach 1:
The control system performs preliminary calculations to determine the required compressor output pressure by adding the blowing pressure and the differential pressure before the actual blowing operation. This preliminary action allows the compressor to be pre-configured with the exact pressure needed, avoiding energy waste from excessive pressure generation while ensuring sufficient pressure is always available for the blowing process.
Solution Approach 2:
The system dynamically adjusts the compressor's pressure output based on varying blowing requirements by continuously calculating the sum of blowing pressure and differential pressure. This dynamic adjustment capability allows the compressor to operate at optimal pressure levels for each specific blowing operation, reducing energy loss while adapting to changing measurement and pressure requirements.
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 leads to reduced electrical power consumption and operating costs by ensuring the compressor generates only the necessary pressure level, creating a composite system that efficiently manages energy use and minimizes unnecessary pressure increases.
Implementation Method 1
a blow gas is provided by a compressor
Implementation Method 2
the previously tempered preform is expanded into a container by biaxial orientation with the help of compressed air
Data Source
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AI summary
The method and the apparatus serve for blow-moulding containers. After thermal conditioning, a parison is formed into the container within a blowing mould of a blow-moulding machine (41) by the action of blow-moulding pressure. The required blow-moulding gas is provided by a compressor (42). A compressor controller (44) is connected to a controller of the blow-moulding machine in such a way that the controller of the blow-moulding machine generates a setpoint value (49) for the initial pressure which is provided by the compressor.