Stationary Compressed Air Supply with Integrated Leak Detection
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Solution Overview
Problem
Current methods for detecting leaks in high-pressure air systems of stretch blow molding machines are inefficient, requiring labor-intensive and time-consuming processes, and do not allow for precise identification of leak sources or assessment of valve and seal wear, leading to delays and increased costs during assembly and maintenance.
Innovation Solution
A modular compressed air supply device with integrated leak detection capabilities, including a low-pressure connection for leak isolation and a monitoring system to check the tightness of individual valves and seals, allowing for targeted troubleshooting and maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional leak detection methods are used, then the entire compressed air system can be tested, but the process is labor-intensive and time-consuming
Solution Approach 1:
The compressed air system is divided into multiple testable sections (valves, seals, connections) with individual leak detection points. Each component can be isolated and tested separately using the leakage detection device, eliminating the need to test the entire system at once and reducing detection time.
Solution Approach 2:
The manual leak detection process using ears and spray is replaced with an automated leakage detection device that includes sensors and electronic evaluation. The device automatically detects pressure changes and identifies leak locations through electronic signals, reducing both time and labor requirements.
2Reliability
If the entire compressed air system is tested, then leaks can be detected, but the location of leaks cannot be precisely identified
Solution Approach 1:
The system incorporates multiple leakage detection points distributed throughout the compressed air path, allowing precise identification of which specific component (valve, seal, connection) is leaking. Each detection point is associated with a specific component, enabling accurate location identification.
Solution Approach 2:
The leakage detection device provides feedback signals that indicate both the presence of a leak and its location. The evaluation unit processes sensor data to provide targeted information about which specific component is leaking, enabling precise identification without requiring manual inspection.
3Reliability
If manual leak detection is used, then leaks can be found, but extensive identification and repair are required
Solution Approach 1:
Manual inspection using ears and spray is replaced with an automated electronic detection system that identifies leak locations and provides diagnostic information. The system automatically determines which component needs repair, simplifying the overall identification and repair process.
Solution Approach 2:
The system provides automated feedback about leak conditions and component status, enabling rapid identification of problematic areas. This feedback reduces the complexity of diagnostic procedures and guides repair efforts directly to the source of the problem.
4Ease of manufacture
If field assembly is performed, then the machine can be installed at the customer's site, but leaks occur that require further inspections
Solution Approach 1:
The leakage detection system is integrated into the assembly process, allowing leaks to be detected and identified during or immediately after assembly. This preliminary detection prevents the need for separate inspection phases later, reducing overall time despite field assembly 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
Enables faster and more efficient detection and remediation of leaks, reducing downtime and costs by allowing for precise identification of leak sources and improving maintenance planning, thus ensuring the reliability and efficiency of the compressed air system.
Implementation Method 1
a leakage detection device (48) which is suitable and intended to detect leaks in the compressed air supply (4)
Data Source
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AI summary
A device for forming plastic preforms (10) into plastic containers (20) with at least one forming station (2) comprising a blow mold (8) within which the plastic preforms (10) can be formed into the plastic containers (20) by applying a flowable medium, and with an application device (22) which applies the flowable medium to the plastic preforms, wherein the device includes a compressed air supply device (4) which provides the flowable medium and this compressed air supply device (4) is arranged in a stationary position. According to the invention, the compressed air supply device (4) includes a leak detection device which is suitable and intended for detecting leaks in the compressed air supply of the device (1).