Glass Mould Cooling Control Using Fan Working Point Optimization
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Solution Overview
Problem
The glass container manufacturing process is hindered by inefficient mould cooling, leading to increased mould temperature, production defects, and high energy consumption, which limits production rate and causes economic losses due to the complexity of heat exchange between the mould and coolant, influenced by various parameters including air temperature, fan working points, and flow types.
Innovation Solution
A method and system for controlling mould cooling in glass forming machines that involves analyzing mould structure for heat exchange, using sensors to gather data on pressure loss, temperature, and humidity, and performing numerical calculations to optimize fan working points and cooling event timing, ensuring maximum cooling efficiency and reducing energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If traditional mould cooling methods are used, then the cooling process is simple to implement, but the cooling efficiency is insufficient leading to increased mould temperature
Solution Approach 1:
The patent implements dynamic control of cooling parameters including variable fan speeds, adjustable coolant flow rates, and real-time timing adjustments based on mould temperature sensors and production rate requirements, transforming the static cooling system into a dynamic one that adapts to changing conditions
Solution Approach 2:
The system changes multiple cooling parameters simultaneously including fan working points, coolant flow rates, cooling event timing duration, and temperature thresholds to optimize cooling efficiency and achieve the desired mould temperature control
2Temperature
If cooling time is increased to improve cooling efficiency, then mould temperature control improves, but production rate decreases due to timing constraints
Solution Approach 1:
The patent implements periodic cooling events synchronized with the production cycle timing, where cooling is activated at specific intervals and durations within the 360° production cycle, allowing efficient heat removal without continuously extending the production cycle time
Solution Approach 2:
The system performs preliminary cooling actions by pre-cooling the mould before the glass gob is introduced and maintaining optimal temperature during the forming process, reducing the need for extended cooling time after forming
3Productivity
If multiple cooling parameters are adjusted to optimize cooling, then cooling efficiency improves, but system complexity increases
Solution Approach 1:
The patent implements a feedback control system where temperature sensors monitor mould temperature in real-time, and this information feeds back to the controller which automatically adjusts fan speeds, coolant flow rates, and timing parameters to maintain optimal cooling without requiring complex manual intervention
Solution Approach 2:
The control system integrates multiple functions into a single unified controller that manages fan motors, coolant pumps, timing sequences, and temperature monitoring simultaneously, reducing overall system complexity despite controlling multiple parameters
4Temperature
If high fan working points are used to increase cooling capacity, then cooling efficiency improves, but energy consumption increases
Solution Approach 1:
The patent dynamically adjusts fan working points based on real-time temperature sensor readings and production rate requirements, operating fans at variable speeds rather than fixed high speeds, thereby reducing energy consumption while maintaining adequate cooling capacity
Solution Approach 2:
The system optimizes the combination of fan speed, coolant flow rate, and timing parameters to achieve maximum cooling efficiency at minimum energy consumption, rather than simply maximizing fan speed
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 mould cooling, reduces production waste, increases production rate, and lowers energy consumption, enabling better control over the annealing process and extending mould lifespan, while minimizing defects and operational costs.
Implementation Method 1
The moulds deployed on the blank moulds, as well as those deployed on the blow moulds differ from each other in terms of the forming material being used, the type of cooling... The principle of operation is similar to the above with the difference that the air is supplied by the hangers, on which the mould is mounted... Cooling can be realised through 360° of the production cycle.
Data Source
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AI summary
The object of the invention is a method for controlling the cooling process during forming of glass containers in an IS type glass forming machine, including the steps of analysing the mould structure in terms of heat exchange between the glass, the mould, and the coolant, receiving data from the sensors concerning pressure losses in the conduit supplying the coolant to the mould, pressure losses in the glass forming machine, up to the moment of entering the mould by the coolant, gob temperature before being fed into the mould, air temperature in the conduit, after completing the compression work by the fan, and air humidity, and introducing it to the calculation module, introducing the desired production rate and maximum time of realising the cooling event in the timing, as well as the type of material the mould is made of, into the calculation module, performing numerical calculations in the calculation module in order to derive the fan working point ensuring maximum efficiency of the cooling system. The object of the invention is also a system realising said method.