Heating Device Preform Lock for Synchronization Time Reduction
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current plastic container treatment systems experience significant time losses and reduced efficiency due to synchronization issues and faults, particularly when a downstream device fails, leading to overheating and discarding of preforms.
Innovation Solution
A method and device where the supply of plastic preforms to the heating device is allowed to resume during the synchronization period after a fault, and the preform lock is activated early to minimize downtime, allowing for earlier restart of production by synchronizing the heating device with other machines before the synchronization is fully achieved.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the heating device and further treatment device are operated synchronously, then production efficiency is improved, but when a fault occurs in the downstream treatment unit, the heating unit must stop and empty itself, causing time losses of up to 15 seconds
Solution Approach 1:
The preform lock is reopened at the start of the synchronization period before actual synchronization is achieved, allowing plastic preforms to be fed into the heating unit in advance. This preliminary action enables production to begin earlier by up to 15 seconds, as the heating unit can start processing preforms while the downstream treatment unit is still resynchronizing.
Solution Approach 2:
A barrier device is positioned in the transport path of plastic preforms to the heating unit. When a fault occurs downstream, the barrier can be activated to temporarily block preforms from entering the heating unit, preventing overheating and waste while allowing the system to resynchronize without complete shutdown.
2Reliability
If the downstream treatment unit stops due to a fault, then the fault can be rectified, but the heating unit must run empty and remove already heated preforms, causing efficiency reduction
Solution Approach 1:
The preform lock reopening at the start of synchronization allows the heating unit to immediately begin processing new preforms while downstream units are being repaired, eliminating the need to run empty and removing the productivity penalty associated with fault rectification.
Solution Approach 2:
The barrier device extracts or separates the fault management function from the heating unit operation. When faults occur downstream, the barrier isolates the heating unit from the affected downstream processes, allowing independent fault rectification without forcing the heating unit to stop and empty itself.
3Productivity
If plastic preforms are fed continuously into the heating unit, then production flow is maintained, but when downstream units fail, preforms overheat quickly and must be discarded
Solution Approach 1:
The barrier device acts as an intermediary between the preform supply and the heating unit. When downstream faults occur, the barrier can be activated to block preforms from entering the heating unit, preventing overheating while allowing the system to maintain production flow through resynchronization rather than complete shutdown.
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 reduces time losses and increases efficiency by enabling earlier resumption of production after faults, potentially saving up to 15 seconds of synchronization time and allowing for reuse of preforms that have not exceeded a critical temperature.
Implementation Method 1
plastic preforms are transported by means of a transport device and heated by a heating device during this transport
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
The method involves operating and temporarily synchronizing a heating unit (4) and a treatment device (6). A supply of plastic containers is disrupted to the heating unit during predetermined synchronization period in synchronization with the heating unit in time after occurrence of the fault condition when a fault condition occurs in one of the heating units arranged downstream of the treatment devices by a locking device (12). The supply of the plastic containers is re-admitted to the heating unit during the synchronization period or at the start of synchronization. An independent claim is also included for a device for treating plastic containers with time reduction when synchronizing system components.