Individual Container Marking for Offline Defect Correlation
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Solution Overview
Problem
Existing methods for detecting and tracing defects in container production facilities are inadequate, as they do not allow for precise identification of the cause of malfunctions and require multiple markings that can weaken containers and complicate the installation, while offline tests complicate correlation with production data.
Innovation Solution
A method involving individual identification and marking of each container with a unique timestamp and position information during production, allowing real-time data correlation and predictive maintenance, and a control system to track the container's path and production data.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of information
If multiple markings are applied to trace the container's path through each installation element, then the container's path can be traced, but the installation becomes more complex and the container is weakened by increased marked areas
Solution Approach 1:
The patent merges multiple separate marking operations into a single integrated marking step. Instead of marking the container at each installation element (forming machine, filling machine, processing machines), the system applies one comprehensive marking that encodes the container's path information through all elements. This single marking contains position information about multiple stations, eliminating the need for multiple separate marking operations and reducing installation complexity while maintaining full traceability.
Solution Approach 2:
The single marking applied to the container serves multiple functions simultaneously: it identifies the container, traces its path through the production line, records position information about multiple installation elements, and provides timestamp information. This multi-functional marking replaces what would otherwise require multiple specialized marking operations at different stations.
2Loss of information
If multiple markings are applied to trace the container's path, then the container's path can be traced, but the container is weakened by increasing the number of marked areas
Solution Approach 1:
The patent consolidates multiple marking operations into a single marking step, thereby limiting the total number of marked areas on the container to one location. This single marking contains all necessary path traceability information, preventing the cumulative weakening that would result from multiple separate marking operations at different installation elements.
3Reliability
If sensors are installed to detect defective containers, then defective containers can be detected, but the cause of the malfunction cannot be traced
Solution Approach 1:
The system implements feedback by encoding position information about the installation elements in the container marking. When a defect is detected by sensors, the position information in the marking provides feedback about which specific element the container was processed by, enabling traceability of the defect cause back to the specific installation element responsible.
Solution Approach 2:
The system performs preliminary action by marking the container with position information about all installation elements before the container leaves the facility. This pre-recorded information is available immediately when defects are detected, eliminating the need for separate investigative procedures to determine the cause of malfunctions.
4Measurement precision
If offline tests are performed to analyze defects, then broader analysis is possible, but the link to the facility's control system is broken and correlation with production data is difficult
Solution Approach 1:
The system performs preliminary action by recording position information and timestamp information in the container marking before the container leaves the facility. This pre-recorded identification information remains with the container through offline testing, enabling correlation between offline test results and the specific production data from the facility's control system without breaking the link.
Solution Approach 2:
The container marking serves as an intermediary that carries identification information between the production facility and offline testing. The position information and timestamp information encoded in the marking act as a bridge, allowing correlation of offline test results with production data from different systems and time periods.
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 precise identification and traceability of containers, facilitating fault analysis and predictive maintenance by linking production data with offline tests, reducing the need for multiple markings and simplifying the detection of malfunctions.
Implementation Method 1
each preform being held individually and heated to a reference temperature
Data Source
Figure 1
Figure 2~5
AI summary
A method for producing a series of containers from a series of preforms made of plastic materials heated in a container production installation comprising at least one preform heating station, a forming machine comprising a plurality of forming stations, and one or more processing machines, each comprising a plurality of processing stations. The method comprises the following steps: forming the series of preforms in the forming machine; processing the series of individual containers in the processing machine; and circulating each individually held container between the forming machine and the processing machine(s). The method comprises a phase of individual identification of each container produced during a predetermined monitoring period.individual identification phase including a marking step during which each individual container produced during said monitoring period receives a marking specific to said container, allowing said container to be individually identified and distinguished from all other containers produced by the production facility during said monitoring period.