Cyclical Production Parameter Zone for Stable Quality Output
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Cyclical production processes, such as injection molding, are susceptible to instability due to external influences like air temperature, pressure, and humidity, leading to quality losses and rejects, as existing methods struggle to maintain process stability without operator intervention.
Innovation Solution
The formation of a process parameter zone is automated before production, where process parameters are simulated to ensure stability, allowing for automated checks to confirm that the parameters remain within stability limits, reducing the need for continuous quality checks during production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If continuous quality checks are performed during production, then quality consistency is improved, but time consumption and operational complexity increase
Solution Approach 1:
The patent applies preliminary action by creating a process parameter zone before production starts. The system pre-determines stable process parameters and establishes acceptance criteria (process parameter zone) in advance. During production, only simple checks are needed to verify if parameters remain within this pre-established zone, eliminating the need for continuous detailed quality inspections while maintaining quality consistency.
2Stability of the object's composition
If manual monitoring and adjustment of process parameters is performed, then process stability can be maintained, but operator time and effort increase
Solution Approach 1:
The system applies self-service by automatically monitoring process parameters and comparing them against the pre-established process parameter zone. The system self-adjusts by automatically identifying when parameters drift outside the stable zone and triggers appropriate responses, eliminating the need for continuous manual operator intervention while maintaining process stability.
3Manufacturing precision
If process parameters are frequently adjusted to maintain stability, then quality tolerance is improved, but production efficiency decreases
Solution Approach 1:
The patent establishes a process parameter zone before production that defines the acceptable range for stable processing. This pre-established zone allows parameters to vary within defined limits without triggering adjustments, reducing the frequency of parameter changes while maintaining quality tolerance. Production can proceed efficiently with minimal interruptions for adjustment.
Data Source
Figure 1~6
Figure 2
Figure 3~4
AI summary
The invention relates to a method for carrying out a cyclical production process, in which production process goods are produced; wherein the production process is adjusted via at least one process adjustment variable; wherein at least one quality feature of the produced goods and at least one quality tolerance of the produced goods are predefined; wherein at least one process adjustment variable is changed; wherein at least one process characteristic variable variant (KE', KE'', KE''') is determined for a changed process adjustment variable in an automated manner; wherein a check is carried out in an automated manner in order to determine whether the determined process characteristic variable variant (KE', KE'', KE''') is within a process stability limit (SG) and is process-stable; wherein a check is carried out in order to determine whether the quality feature of the goods produced with a changed process adjustment variable is within the quality tolerance of the produced goods and acceptable parts have therefore been produced; and wherein a process characteristic variable zone (EO) is formed in an automated manner using at least one determined process characteristic variable variant (KE', KE'', KE''') which is process-stable and the process adjustment variable of which produces acceptable parts.