Container Treatment System Throughput Synchronization
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Solution Overview
Problem
Container treatment systems face challenges in reliably controlling the operation of various machines to adapt to changing container throughput, particularly in direct printing machines, which can lead to adverse effects on container surface properties and print quality due to downtimes and uneven container spacing.
Innovation Solution
A container treatment system with a system control device that adjusts the operation of upstream container treatment machines and transport devices based on the container throughput of the direct printing machine, including changing container spacing and using buffer regions to manage throughput changes, ensuring consistent and high-quality printing results.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the direct printing machine operates at varying throughput, then printing flexibility is improved, but container surface properties and print quality deteriorate due to downtimes and uneven spacing
Solution Approach 1:
The system performs preliminary actions by having upstream container treatment machines (cleaning, drying, pretreatment) continue operating at their optimal speeds and fill a buffer region with containers before the direct printing machine experiences downtime or throughput changes. This ensures that when the printing machine needs to adjust its throughput, containers are already available in the buffer, preventing interruptions and maintaining consistent container spacing, thereby preserving print quality while allowing printing flexibility.
2Productivity
If upstream container treatment machines operate at high speed, then productivity is improved, but container accumulation occurs when direct printing machine throughput changes
Solution Approach 1:
The system introduces a buffer region as an intermediary between the upstream container treatment machines and the direct printing machine. This buffer region acts as a mediator that absorbs the mismatch between the high-speed operation of upstream machines and the variable throughput of the printing machine. Containers are temporarily stored in this buffer zone, allowing upstream machines to maintain high productivity while ensuring that containers are supplied to the printing machine at the correct spacing, preventing accumulation and maintaining uniformity.
3Reliability
If the system uses buffer regions to manage throughput changes, then print quality is maintained, but device complexity increases
Solution Approach 1:
The system employs feedback control where the control device continuously monitors the throughput of the direct printing machine and the status of the buffer region. Based on this feedback information, the control device automatically adjusts the operation of upstream container treatment machines and transport devices. This feedback mechanism maintains print quality consistency by ensuring proper container spacing and timing, while the automated control reduces the perceived complexity by managing system coordination without requiring manual intervention.
Data Source
AI summary
Container treatment system for treating containers, such as bottles, with at least one direct printing machine for applying a print image onto containers and at least one container treatment machine arranged upstream of the direct printing machine and a system control device, where the system control device is configured to control the operation of the container treatment machine in dependence of a change of the container throughput that can be obtained with the direct printing machine.