Hot Glass Container Control Using Thermal Imaging and Wall Thickness

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Solution Overview

Problem

Existing systems for monitoring and controlling hot glass containers in IS machines rely heavily on operator skill and lack accurate feedback for correcting temperature and wall thickness issues, leading to suboptimal process yield and quality.

Innovation Solution

A closed loop temperature and wall thickness-based control system that combines thermal imaging and on-line wall thickness measurement to generate separate feedback signals for temperature and thickness variations, using a signal processing module to estimate temperatures and adjust machine parameters for improved control.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If thermal imaging is used to monitor hot glass containers, then temperature information is obtained, but wall thickness information cannot be accurately determined due to signal overlap

Engineering Contradiction:

Improvehot glass container temperatureVSAvoidwall thickness measurement accuracy

Core Design Contradiction:

TemperatureVSMeasurement precision

Solution Approach 1:

The patent segments the thermal radiation signal into two distinct components: one representing temperature information and another representing wall thickness information. By mathematically separating these overlapping signals, the system can independently measure both parameters with high precision, resolving the contradiction between obtaining temperature data and maintaining wall thickness measurement accuracy.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent introduces a signal processing module as an intermediary that receives the combined thermal radiation signals from the hot glass containers and processes them to extract separate temperature and wall thickness information. This intermediary component enables the system to handle the overlapping information and produce distinct measurements for both parameters.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Extent of automation

If automatic closed loop control is implemented using thermal imaging data, then operator skill dependence is reduced, but control accuracy deteriorates due to inability to separately correct temperature and thickness issues

Engineering Contradiction:

Improveautomatic control of I.S. machineVSAvoidcontainer quality control accuracy

Core Design Contradiction:

Extent of automationVSManufacturing precision

Solution Approach 1:

The patent implements a feedback-based automatic closed loop control system that uses the separately extracted temperature and wall thickness information to automatically adjust I.S. machine parameters. The system continuously monitors both parameters and provides feedback control signals to maintain optimal container quality, achieving high automation without sacrificing precision.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent enables independent adjustment of manufacturing parameters based on separate temperature and wall thickness measurements. The control system can modify specific process parameters to correct temperature deviations while maintaining wall thickness specifications, or vice versa, allowing precise control of each parameter independently despite high automation.

Inventive Principle:

Principle #35Parameter changes

3Device complexity

If thermal radiation intensity signals are used for both temperature and wall thickness information, then measurement system complexity is reduced, but information accuracy deteriorates due to signal overlap

Engineering Contradiction:

Improvemeasurement system structureVSAvoidseparation of temperature and thickness data

Core Design Contradiction:

Device complexityVSLoss of information

Solution Approach 1:

The patent extracts separate temperature and wall thickness information from the combined thermal radiation intensity signals through mathematical processing. By taking out and separating these two information components from the overlapping signals, the system maintains simple measurement hardware while recovering complete and accurate information for both parameters.

Inventive Principle:

Principle #2Taking out (Extraction)

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

This system enhances process yield and quality by reducing operator dependence, providing accurate corrective actions based on real-time feedback, leading to consistently produced hot glass containers with desired characteristics.

Implementation Method 1

a thermal imaging measurement device adapted to generate intensity output signals representative of the intensity of the thermal radiation from hot glass containers

Methodology Applied

Scientific EffectThermal radiation: Thermal Radiation

Data Source

PatentEP2873652B1Utilization of wall thickness measurement in combination with thermal imaging of containers

Publication Date: 2022.04.20 EMHART GLASS SA

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AI summary

A closed loop temperature and wall thickness-based control system (48) for improving process yield and quality while reducing dependence on operator skill utilizes intensity information (38) from a hot end container imaging system (30) and wall thickness information (40) from a hot glass container wall thickness measurement system (32). By utilizing both the container intensity information and the measured wall thickness information it is possible to provide separate feedback signals responsive to temperature variations and thickness variations. These signals are used to implement automatic closed loop control of the I.S. machine.