Flat Film Die Exit Gap Control with Simultaneous Adjusting Bolts
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Solution Overview
Problem
Existing flat film machines require manual and sequential adjustment of adjusting bolts for die exit gap, leading to time-consuming setup, downtime, and quality dependence on operator experience, with adjustments often made during production, resulting in inefficiencies and inconsistent product quality.
Innovation Solution
An adjusting device with adjusting bolts capable of simultaneous automated or semi-automated base and process strokes, allowing for reproducible and time-efficient adjustment of the nozzle exit gap, enabling production during setup and ensuring consistent product quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual sequential adjustment of adjusting bolts is performed, then the die exit gap can be adjusted, but the setup time increases and production downtime increases
Solution Approach 1:
The system performs preliminary action by automatically positioning all adjusting bolts to their starting positions before production begins. The control system stores the required adjustment values and automatically executes the positioning sequence, eliminating the need for manual sequential adjustment and reducing setup time while ensuring consistent positioning accuracy.
Solution Approach 2:
The patent replaces the manual mechanical adjustment system with an automated control system that uses a control unit to manage the adjusting bolts. The control system receives target values, calculates required adjustments, and automatically actuates the bolts, substituting manual operation with automated control to reduce setup time and improve consistency.
2Manufacturing precision
If manual adjustment is performed, then the die exit gap can be set, but the quality depends on operator experience and sensitivity
Solution Approach 1:
The control system incorporates feedback mechanisms to monitor and verify the position of adjusting bolts and the resulting die exit gap dimensions. By comparing actual measurements with target values and automatically making corrective adjustments, the system ensures consistent positioning accuracy independent of operator experience or sensitivity.
Solution Approach 2:
The manual mechanical adjustment process is replaced with an automated control system that programmatically manages bolt positioning. The control unit stores predefined adjustment values and executes them consistently, eliminating variability introduced by human operators and ensuring reliable, repeatable adjustment quality.
3Manufacturing precision
If sequential adjustment of multiple adjusting bolts is performed, then each bolt can be adjusted individually, but the adjustment process becomes very time-consuming
Solution Approach 1:
The patent merges the adjustment operations of multiple adjusting bolts into a single coordinated process. The control system manages all bolts simultaneously, allowing parallel adjustment operations that complete all individual bolt positioning in one efficient sequence rather than requiring separate manual operations for each bolt, thereby significantly improving setup efficiency.
Solution Approach 2:
The control system performs preliminary calculation and sequencing of all required adjustments before execution. By pre-planning the adjustment sequence and coordinating multiple bolts simultaneously, the system completes all individual adjustments in a single efficient operation cycle, eliminating the time-consuming sequential manual adjustment process.
Data Source
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AI summary
The invention relates to an adjusting device (10) for controlling an exit thickness (AD) of a nozzle exit gap (110) of a flat film machine (100), having a plurality of adjusting pins (20) for carrying out an adjusting movement for changing the exit thickness (AD), the adjusting pins (20) having an adjusting range (SB) between a closing end position (SE) and an opening end position (OE), the adjusting range (SB), proceeding from the opening end position (OE), furthermore having a basic travel path (BH) for a basic adjustment of the exit thickness (AD) and, proceeding from the closing end position (SE), having a process travel path (PH) for process controlling the exit thickness (AD).