Conveyor Shuttles with Adjustable Spacing for Heating Tunnels
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing thermoplastic container manufacturing plants face inefficiencies due to long and bulky heating tunnels, wasted energy from large preform pitches, and the need for costly pitch-changing devices to adapt preform spacing for different processing stations.
Innovation Solution
A conveyor system with individually controlled shuttles that adjust their spacing along a heating path to optimize energy use, reduce tunnel length, and maintain preform alignment for seamless transfer to subsequent processing stations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If preforms are transported through a heating tunnel with large pitch between successive preforms, then the heating tunnel can be simpler in design, but a large part of the heating radiation is wasted and energy efficiency deteriorates
Solution Approach 1:
The conveyor system employs dynamically adjustable pitch between successive preforms during heating. The pitch is not fixed but can be varied along the heating path to optimize energy utilization while maintaining manageable system complexity through controlled movement adjustments.
Solution Approach 2:
The system changes the spatial parameter (pitch distance) between preforms during the heating process. By adjusting the pitch parameter dynamically, the system maximizes heating radiation absorption efficiency without requiring overly complex structural modifications to the heating tunnel.
2Manufacturing precision
If the heating tunnel is made longer to improve heating quality, then heating effectiveness increases, but the tunnel becomes more bulky and occupies more space
Solution Approach 1:
The heating process maintains continuous and optimized thermal action on preforms by adjusting their spacing dynamically. This ensures that heating effectiveness is maximized throughout the entire heating path, allowing for more efficient use of heating zones and potentially reducing the overall tunnel length required to achieve the same heating quality.
Solution Approach 2:
By implementing dynamic pitch adjustment, the system optimizes the continuous heating process, ensuring that preforms receive adequate thermal treatment without requiring excessive tunnel length. The dynamic control allows for compact tunnel design while maintaining heating quality.
3Adaptability or versatility
If pitch-changing devices are added to adapt preform spacing for different processing stations, then adaptability improves, but device complexity and cost increase
Solution Approach 1:
The conveyor system is designed with universal pitch adjustment capability that serves multiple functions: optimizing heating efficiency, adapting to different processing station requirements, and maintaining flexibility for various production scenarios. This multi-functionality reduces the need for separate specialized pitch-changing devices at different stages.
Solution Approach 2:
The system employs dynamic pitch control that can be adjusted continuously to meet different processing requirements. This dynamic adaptability allows a single conveyor system to handle various pitch requirements without adding multiple static pitch-changing devices, thereby reducing overall system complexity while maintaining high versatility.
4Loss of energy
If individually controlled shuttles are used to adjust spacing, then energy efficiency and adaptability improve, but control system complexity increases
Solution Approach 1:
The conveyor system is divided into independently controllable shuttles, each capable of individual pitch adjustment. This segmentation allows for precise control of preform spacing to minimize heating radiation waste, while the modular nature of individual shuttle control simplifies the overall control architecture compared to a fully centralized system.
Solution Approach 2:
Each shuttle is equipped with individual control capabilities, allowing it to autonomously adjust its position and spacing relative to other shuttles. This self-service approach enables each unit to contribute to overall energy efficiency without requiring complex inter-shuttle coordination, thereby reducing control system complexity while achieving the desired energy optimization.
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
The system enhances energy efficiency by reducing wasted heat, allows for a more compact heating tunnel, and eliminates the need for expensive pitch-changing devices, thereby improving overall manufacturing efficiency and reducing costs.
Implementation Method 1
a heating tunnel defining a heating path; the rail having a heating section for transporting the hollow bodies along the heating path
Data Source
Figure 1~4
Figure 5~6
AI summary
The invention relates to a conveyor (20) for hollow bodies (12) through a heating station (14) for an installation (10) for manufacturing containers made of thermoplastic material, comprising: - a heating tunnel (18) defining a heating path; - a conveyor (20) comprising at least one conveyor rail (22) forming a circuit and shuttles (24) capable of traveling along the rail (22) carrying at least one hollow body (12), each shuttle (24) being individually controlled in movement, the rail (22) having a heating section (22B) for transporting the hollow bodies (12) along the heating path; - a device (32) for entering the hollow bodies (12) to be heated, bringing the hollow bodies (12) to a loading section (22A) of the conveyor rail (22) for loading onto the shuttles (24).two successive shuttles (24) operating with a first entry gauge (E1) determined on this loading section (22A); - a device (38) for the discharge of hot hollow bodies (12) which recovers the hollow bodies (12) loaded onto the shuttles (24) circulating on a section (22C) of the unloading rail (22) of the conveyor. Said conveyor is remarkable in that each shuttle (24) comprises a first support element (26A) for a first hollow body (12) and a second support element (26B) for a second hollow body (12), each shuttle (24) thus being capable of simultaneously carrying two hollow bodies (12), the support elements (26A, 26B) of a shuttle (24) being mounted movably on said shuttle (24) between an extended position in which the support elements (26A, 26B) are separated from said first inlet gap (E1) according to the direction of movement of the shuttle (24), and a close position in which the elements (26A,26B) support units are brought closer together along the direction of travel of this shuttle (24), such that two successive shuttles (24) traveling on the unloading section (22C) are separated by a determined exit spacing (E3) which is different from the first entry spacing (E1).