Container Production Control Using Material State Measurement
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Solution Overview
Problem
Existing production systems for containers suffer from undesired quality fluctuations and fault states due to insufficient consideration of visually imperceptible material characteristics and intensive state variables, which are not systematically analyzed or corrected, hindering process optimization.
Innovation Solution
A method and system that measure visually imperceptible material characteristics and intensive state variables of container components, using inspection units to adjust production processes through open-loop/closed-loop control, incorporating these measurements into a physical calculation model for simulation and adaptive process control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional visual inspection methods are used to check container components, then the inspection process is simple and quick, but visually imperceptible material characteristics and intensive state variables cannot be detected, leading to quality fluctuations
Solution Approach 1:
The patent replaces conventional visual inspection methods with measurement techniques that detect visually imperceptible properties. Inspection units measure material characteristics (such as elasticity, viscosity, or other physical properties) and intensive state variables (such as temperature, pressure, or concentration) of container components and materials, enabling detection beyond human visual capabilities without requiring complex manual inspection procedures
Solution Approach 2:
The patent introduces inspection units as intermediary devices between the production process and control system. These units serve as mediators that measure material characteristics and state variables, transmit this information to the control system, and enable automated adjustments without requiring direct human intervention in the measurement process
2Manufacturing precision
If production processes are operated with fixed parameters, then the control system is simple, but quality fluctuations occur due to variations in material characteristics and intensive state variables
Solution Approach 1:
The patent transforms the control system from a static, fixed-parameter approach to a dynamic system that continuously adapts production parameters. The control system receives real-time measurements of material characteristics and intensive state variables from inspection units and automatically adjusts production process parameters (such as temperature, pressure, speed, or other process variables) to compensate for material variations, thereby maintaining consistent quality despite changes in input materials
Solution Approach 2:
The patent implements a closed-loop feedback control system where measurement results from inspection units are continuously fed back to the control system. This feedback mechanism enables the control system to monitor material characteristics and state variables in real-time and make automatic adjustments to production processes, ensuring quality consistency without requiring manual intervention or complex manual control procedures
3Reliability
If comprehensive measurements of material characteristics are implemented, then quality control improves, but measurement and inspection time increases
Solution Approach 1:
The patent performs measurements of material characteristics and intensive state variables at the input side of the production process, before the actual production operations begin. This preliminary measurement approach allows the control system to pre-adjust production parameters based on measured material properties, ensuring quality control without adding time during the critical production phases. The inspection occurs in parallel with or before material feeding, minimizing impact on production throughput
Data Source
AI summary
The invention relates to a production system for producing, processing and/or filling containers and to a method for the production control and/or system specification of this production system. According to the invention, at least one visually imperceptible intensive state variable or material characteristic of components of the containers, which components are provided as solid bodies, is measured in the area of the production system with respect to the batch and/or object in question. Furthermore, at least one production process proceeding therein for treating and/or transporting the components/containers by machine is controlled on the basis of the measured material characteristic and/or intensive state variable. In this way, quality fluctuations of the components can be quantified and can be used both in the control and in a simulation of the individual production processes in order to optimize these production processes and the associated process units.