Closed Loop Cyclic Timing Optimizer for IS Glass Machines
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Solution Overview
Problem
Existing IS machine systems lack an automated method to optimize event timing based on the characteristics of hot glass containers, relying heavily on operator skill and manual adjustments, which limits process yield and quality.
Innovation Solution
A closed-loop system that utilizes container measurement information from hot glass containers to automatically adjust machine timing, ensuring desired process durations and avoiding mechanical interference, by transforming desired thermal forming durations into machine timing signals and applying them to the IS machine.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual adjustment of machine timing by operators is used, then flexibility in adjusting timing parameters is maintained, but productivity and quality are limited due to dependence on operator skill
Solution Approach 1:
The system implements a closed-loop feedback mechanism where container measurement data from the hot end is continuously fed back to the controller, which automatically adjusts machine timing parameters. This eliminates dependence on manual operator skill while maintaining optimal timing through real-time data-driven adjustments, thereby improving productivity and quality consistency.
Solution Approach 2:
The patent replaces the manual mechanical adjustment system with an automated electronic control system. The controller receives measurement data and automatically computes and applies timing adjustments without requiring manual intervention, substituting human operator skill with automated computational algorithms that consistently optimize machine timing.
2Productivity
If automated timing optimization is implemented, then productivity and quality are enhanced, but system complexity increases
Solution Approach 1:
The controller serves multiple functions: it collects container measurement data, processes the data to determine timing adjustments, communicates with the machine timing system, and implements the optimizations. By consolidating these functions into a single multi-functional controller, the system achieves automated timing optimization without proportionally increasing overall system complexity.
Solution Approach 2:
The system introduces a communication interface as an intermediary between the container measurement system and the machine timing control. This intermediary translates measurement data into timing adjustment parameters, enabling automated optimization while managing system complexity through modular architecture and standardized communication protocols.
3Manufacturing precision
If real-time monitoring of hot glass containers is performed, then quality information is obtained for optimization, but measurement and detection difficulty increases
Solution Approach 1:
The system replaces direct physical contact measurement methods with non-contact optical measurement technology. Containers are measured while moving through the production line without stopping or requiring manual handling, using optical sensors to capture geometric and quality data from hot containers in real-time, thereby overcoming the difficulties of measuring hot, moving objects.
Data Source
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AI summary
The invention relates to a system and method that automatically optimizes the cycles of events occurring in an I.S. machine by using information relating to the characteristics of the hot glass containers manufactured by the I.S, machine obtained by monitoring the containers immediately subsequent to their manufacture. A measurement system (144) provides measurement information indicative of certain characteristics of hot glass containers (142) manufactured by the I.S. machine (140). A controller (154) uses the container measurement information to produce desired process durations (158) used to operate the I.S. machine to produce glass containers having desired characteristics. A cyclic timing adjustment system (160) automatically transforms the desired process durations from the controller (154) into machine timing signals (162) which are applied to the I.S, machine (140) by imposing constraints to maintain a predetermined cyclic order, to avoid mechanical interference or collisions, and to maintain a predetermined total or common cycle period.