Automated Film Machine Changeover Device
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Solution Overview
Problem
The existing methods for changing film products in flat film machines are time-consuming and lack reproducibility due to manual adjustments of multiple parameters, leading to increased changing time and dependence on operator experience.
Innovation Solution
A changing device comprising a sensor module to acquire production parameters, an adjusting module for controlled parameter changes, and a controlling module to optimize the changing process, enabling automated or partially automated changes and reducing the changing time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual adjustment of production parameters is used, then flexibility in changing products is maintained, but changing time increases and reproducibility decreases
Solution Approach 1:
The control module stores optimal parameter settings for different film products in advance. When a product change is required, the system retrieves pre-calculated parameters from memory, eliminating the need for time-consuming manual adjustments during the changing process.
Solution Approach 2:
The patent replaces manual mechanical adjustment with an automated control system that uses sensors to detect current parameters and electronically controls actuators to adjust production parameters, significantly reducing changing time while maintaining flexibility.
2Reliability
If manual adjustment of production parameters is used, then operator experience can guide changes, but reproducibility of changing quality decreases
Solution Approach 1:
The sensor module continuously monitors production parameters and feeds this information back to the control module. This closed-loop feedback system ensures that parameter adjustments are precise and reproducible, eliminating variability caused by different operators' experiences and skills.
Solution Approach 2:
The control system automatically detects current production parameters, retrieves appropriate target values from storage, and executes adjustments without human intervention. This self-service capability ensures consistent, reproducible changing quality independent of operator expertise.
3Manufacturing precision
If iterative sequential changing steps are used, then thorough parameter adjustment is achieved, but changing time significantly increases
Solution Approach 1:
The system performs parameter adjustments continuously and simultaneously rather than sequentially. Multiple parameters are adjusted in parallel based on pre-calculated optimal values, maintaining thoroughness of adjustment while eliminating the time loss associated with iterative sequential steps.
Solution Approach 2:
Optimal parameter combinations are calculated and stored in advance for different product transitions. This preliminary preparation allows the system to execute changes directly without iterative adjustments, achieving both precision and speed.
Data Source
AI summary
The invention relates to a changing device (10) for a changing of a flat film machine (100) from a feed product (EP) to a follow-on product (FP), comprising a sensor module (20) for acquiring at least one production parameter (PP) of the flat film machine (100) and an adjusting module (30) for a controlled change of this acquired at least one production parameter (PP), further comprising a controlling module (40) for controlling the adjusting module (30) for an optimized changing time (TU) for the acquired at least one production parameter (PP) from the feed product (EP) to the follow-on product (FP).