Extrusion Recipe Change Control for Low-Waste Film Transitions
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Solution Overview
Problem
Existing methods for changing recipes in extrusion devices rely heavily on operator experience, leading to high rejection rates, inconsistent quality, and significant material waste due to manual process changes.
Innovation Solution
A method involving automated control of extrusion devices to detect setpoint parameters, plan preparatory operations, and adjust process parameters during ongoing production to minimize material waste and reduce changeover time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual process change is performed by machine operator, then flexibility in handling different recipes is maintained, but quality consistency and changeover efficiency deteriorate due to operator experience dependency
Solution Approach 1:
The system performs preliminary actions by automatically detecting the next recipe requirements and pre-adjusting process parameters before the actual recipe change occurs. This includes pre-heating extruders, pre-adjusting screw speeds, and pre-configuring processing parameters based on the upcoming recipe, thereby eliminating the need for manual intervention and ensuring consistent quality transitions.
Solution Approach 2:
The patent replaces the manual mechanical operation of changing recipes with an automated control system that uses sensors, processors, and actuators. The control system automatically detects recipe changes, calculates optimal parameters, and executes adjustments without human intervention, substituting manual mechanical operations with automated electronic control to ensure precision and consistency.
2Ease of operation
If manual process change is performed, then operator judgment can handle complex situations, but changeover time increases and material waste occurs due to lack of real-time optimization
Solution Approach 1:
The system replaces manual operator judgment with an automated control system that uses sensors, algorithms, and real-time data processing to optimize changeover operations. The control system continuously monitors process parameters and automatically adjusts settings based on the upcoming recipe requirements, eliminating the time delay associated with manual decision-making and execution.
Solution Approach 2:
The control system performs preliminary calculations and preparations for the next recipe change in advance, determining optimal parameter adjustments before the actual transition is needed. This includes pre-calculating temperature profiles, screw speeds, and processing parameters, allowing the system to execute changes rapidly without waiting for manual assessment or gradual adjustments.
3Loss of substance
If process parameters are adjusted during ongoing production, then material waste is reduced, but process stability may deteriorate without proper control
Solution Approach 1:
The system implements continuous feedback control by monitoring process parameters in real-time during ongoing production and automatically adjusting settings based on detected deviations and upcoming recipe requirements. Sensors continuously measure temperature, pressure, flow rates, and other critical parameters, feeding this data back to the control system which makes real-time adjustments to maintain process stability while minimizing material waste during transitions.
Solution Approach 2:
The control system performs preliminary parameter adjustments in a controlled manner during ongoing production, gradually transitioning from current to target parameters rather than making abrupt changes. This includes staged temperature adjustments, progressive screw speed changes, and controlled material flow modifications that maintain process stability while preparing for the next recipe, thereby reducing material waste without compromising product quality.
Data Source
AI summary
The invention relates to a method (100) for supporting at least one process change from a manufacturing process (200) for manufacturing a first film material (201) to a subsequent process (210) for manufacturing a second film material (211) in an extrusion device (10). The invention also relates to a computer program product and a system (1).