Blow-moulding Plant Variable Feed Speeds for Cavity Adaptation
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Solution Overview
Problem
Prior art blow-moulding plants for plastic containers lack flexibility and optimized output per hour, as they are limited by the number of moulding cavities, leading to reduced production capacity when the number of cavities changes.
Innovation Solution
A blow-moulding plant with variable feed line speeds and transfer wheel speeds, regulated according to the number of moulding cavities, allowing for proportional adjustment to maintain maximum output capacity regardless of cavity changes, using actuating means and speed regulating mechanisms to optimize production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the number of moulding cavities is reduced to make larger bottles, then the bottle size increases, but the production output per hour decreases
Solution Approach 1:
The feed line speed is made dynamically adjustable through actuating means that can vary the speed proportionally to the number of moulding cavities. When cavities are reduced, the feed line speed increases to compensate, maintaining constant production output while allowing larger bottle sizes.
Solution Approach 2:
The system changes the operational parameter of feed line speed based on the number of moulding cavities. By regulating the feed line speed as a variable parameter that responds to cavity count changes, the system optimizes production output for different bottle sizes and configurations.
2Productivity
If the feed line speed is increased to compensate for fewer cavities, then production output is maintained, but the synchronization with the blow-moulding line becomes difficult
Solution Approach 1:
The actuating means incorporates feedback mechanisms that detect the number of moulding cavities and automatically adjust the feed line speed accordingly. This closed-loop control ensures proper synchronization between the feed line and blow-moulding line while maintaining optimal production output.
Solution Approach 2:
The actuating means serves multiple functions: it controls feed line speed, responds to cavity count changes, and maintains synchronization with the blow-moulding line. This multi-functional component reduces overall system complexity by consolidating control functions.
3Productivity
If the plant is designed for two-cavity moulding units to maximize output, then production capacity is doubled, but flexibility to produce different bottle sizes is reduced
Solution Approach 1:
The system transitions from a fixed configuration optimized for two cavities to a dynamic system where feed line speed can be adjusted for any number of cavities. This allows the plant to maintain high production capacity with two cavities while also being flexible to operate with one cavity for larger bottles or other configurations.
Solution Approach 2:
The actuating means enables parameter changes in feed line speed based on the actual number of moulding cavities in use. This allows the same physical plant to adapt its operational parameters to different bottle sizes and production requirements, maximizing both capacity and flexibility.
Data Source
Figure 1
Figure 2
Figure 3a~4d
AI summary
A plant for blow-moulding plastic containers (2) from respective parisons (3) is equipped with a plurality of interchangeable moulding units (15), each having a predetermined number of moulding cavities (19) for blow-moulding respective containers (2); with a wheel (39) for feeding the parisons (3) to the respective moulding cavities (19); with a wheel (76) for picking up the containers (2) from the respective moulding cavities (19); and with two lines (41, 79) for feeding the parisons (3) to the first transfer wheel (39); and the containers (2) from the pick-up wheel (76) to a filling machine (10), respectively; the feed speeds of the two feed lines (41, 79) vary according to the number of moulding cavities (19) in the moulding units (15) mounted on the plant at a given time.