Glass Machine Control Unit Mode Switching
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Solution Overview
Problem
In glass container forming machines, operators face challenges in safely adjusting mechanisms between the blank and blow stations without accidental movement, requiring a control system to manage power distribution to prevent collisions while allowing for maintenance and setup operations.
Innovation Solution
A control unit with an operator interface that transitions between modes of operation, supplying power to either the blank or blow station mechanisms, and includes a speed supervision controller to prevent excessive movement during setup, ensuring safe operation by disconnecting power from one station when the other is being adjusted.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If power is supplied to both blank station and blow station mechanisms simultaneously, then operational efficiency is improved, but safety deteriorates due to risk of accidental movement during adjustments
Solution Approach 1:
The control system dynamically switches between different power supply states based on operational mode. In production mode, power is supplied to both stations for continuous operation. In maintenance/setup mode, power is selectively supplied only to the station being adjusted, preventing accidental movement of the other station while allowing necessary adjustments.
Solution Approach 2:
The system changes the power supply parameter selectively to different stations based on the operational mode. The controller receives mode selection input and accordingly adjusts the power supply state - either both stations powered for production, or only one station powered for maintenance, thereby resolving the safety-efficiency contradiction.
2Reliability
If power is disconnected from one station during adjustments, then safety is improved, but operational flexibility deteriorates
Solution Approach 1:
The control system provides dynamic adaptability by allowing operators to select between different power supply configurations. The system can adapt to production requirements (both stations powered) or maintenance requirements (one station powered), providing operational flexibility while maintaining safety through mode-based power management.
Solution Approach 2:
The control system serves multiple functions: it manages power distribution for both production and maintenance modes, selects which station receives power based on operational needs, and provides a unified interface for both operations. This multi-functionality resolves the contradiction by making the power supply system adaptable to different operational requirements.
3Reliability
If mode transition control is implemented, then safety during maintenance is improved, but system complexity increases
Solution Approach 1:
The control system is segmented into distinct functional modules: mode selection input interface, power supply control logic, and station-specific power distribution. This segmentation allows the complex safety control function to be implemented through modular, manageable components rather than a monolithic complex system.
Data Source
AI summary
A control unit configured to control a section of an I.S. machine having a blank station including a first plurality of mechanisms and a blow station including a second plurality of mechanisms is provided. The control unit includes an operator interface configured to receive a first input and a second input from an operator. The control unit includes a controller configured to transition the section from a first mode of operation to a second mode of operation. Upon receipt of the first input the control unit is configured to supply power to either the first or second plurality of mechanisms and not to supply power to the other. The control is configured to move one of the mechanisms to which power is being supplied in the second mode of operation based on the second input received from the operator.