Mold Cooling Air Pressure Control in Hollow Glass Forming
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Solution Overview
Problem
Current hollow glass forming systems lack optimization of air production characteristics to match the operating characteristics of the forming machine, leading to inefficient energy consumption and the need for tedious reprogramming of control units.
Innovation Solution
A secondary control unit is introduced to regulate air production based on the operating characteristics of the forming machine, adjusting cooling times and pressures to meet setpoint temperatures without requiring reprogramming of the primary control unit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If the air production device operates with fixed characteristics, then the control system is simple, but the energy consumption is inefficient and does not match the forming machine's operating characteristics
Solution Approach 1:
The air production device transitions from fixed operating characteristics to dynamic adjustment based on real-time feedback from the forming machine's operating parameters. The control unit continuously monitors forming characteristics and adjusts air production characteristics accordingly, enabling the system to adapt to varying energy demands during different forming operations.
Solution Approach 2:
A feedback mechanism is implemented where the control unit receives operating characteristics data from the forming machine and uses this information to regulate the air production device. This closed-loop control ensures that energy consumption is optimized by matching air production output to the actual forming requirements, eliminating wasted energy while maintaining system simplicity through automated regulation.
2Manufacturing precision
If the cooling time is extended to achieve setpoint temperatures, then the temperature control precision is improved, but the production cycle time increases
Solution Approach 1:
The cooling time is transformed from a fixed predetermined value to a dynamic parameter that adjusts based on real-time temperature monitoring and forming characteristics. The system continuously evaluates the approaching setpoint temperature and modulates the cooling duration, enabling precise temperature control while minimizing unnecessary cooling time that would extend the production cycle.
Solution Approach 2:
The control unit autonomously determines the optimal cooling time by monitoring temperature feedback and comparing it against the setpoint requirements. This self-regulating mechanism eliminates the need for conservative fixed cooling times, allowing the system to achieve precise temperature control exactly when needed and terminate cooling immediately when the setpoint is reached, thereby optimizing both precision and productivity.
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 approach optimizes energy consumption by adapting air production to meet forming conditions, reducing energy demands and maintaining high-quality glass article production.
Implementation Method 1
a flow of air coming from an air production device to cool the molds
Implementation Method 2
This heat extraction, which is governed by complex heat transfer phenomena, necessitates the implementation of appropriate air cooling for the roughing and finishing molds
Data Source
Figure 1
Figure 2
AI summary
The invention relates to a facility (1) for forming a hollow glass item, the facility comprising: a forming machine (10) having a set of moulds (14); a device (50) for producing air that is configured to provide a stream of air for cooling the moulds (12); a primary control unit (20) configured to control the distribution of air to the moulds; and a secondary control unit (30). The primary control unit (20) is configured to regulate the duration of cooling (d) of each mould (12) on the basis of a set temperature (Tc). The secondary control unit (30) is configured to determine a set pressure value (Pc) of the cooling air on the basis of the durations of cooling (d) of the moulds (12) and of the determined time ranges (D) of the moulds (12), which set pressure value is compatible with the mechanical stresses of an operating cycle of the mould (12).