Target Signature Closed Loop Control for IS Machine Timing
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Solution Overview
Problem
Existing glass container manufacturing processes struggle to automatically adjust I.S. machine timing and motions to maintain optimal glass distribution, leading to variations in product quality and increased dependence on operator skill.
Innovation Solution
A system and method that utilize a multipoint, multispectral measurement system to transform pixel data into a reduced dimensional signature, which is then used to adjust event timing signals for the I.S. machine, implementing a target signature closed loop control system to minimize variations and improve process yield and quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If automatic adjustment of I.S. machine timing and motions is implemented, then manufacturing precision and process yield improve, but device complexity increases
Solution Approach 1:
The system implements a closed-loop feedback control mechanism where container measurements are continuously taken after formation, compared against target specifications, and used to automatically adjust I.S. machine timing and motions. This feedback loop enables automatic compensation for process variations, improving glass distribution consistency while managing system complexity through automated control algorithms.
Solution Approach 2:
The patent replaces manual operator adjustment of machine timing and motions with an automated control system that uses measurement data to compute and apply adjustments. This substitution of mechanical/manual operations with automated control systems improves precision while the complexity is managed through software-based control algorithms rather than additional mechanical components.
2Manufacturing precision
If operator skill dependence is reduced through automation, then manufacturing precision improves, but device complexity increases
Solution Approach 1:
The control system performs self-adjustment by automatically computing timing and motion corrections based on measured container characteristics. The system serves itself by using its own measurement capabilities to generate control adjustments, eliminating the need for skilled operators to manually analyze and adjust parameters, thereby improving consistency while managing complexity through autonomous operation.
Solution Approach 2:
Manual operator skills and judgments are replaced with automated control algorithms that process measurement data and generate adjustments. This substitution transfers the expertise requirement from human operators to software systems, improving precision through consistent automated decision-making while managing complexity through programmable control logic.
3Measurement precision
If more measurement points and spectral data are collected, then measurement precision improves, but loss of time in data processing increases
Solution Approach 1:
The system extracts only the most relevant features and characteristics from the extensive measurement data obtained from multiple points and spectral channels. By identifying and extracting key parameters that most significantly impact container quality, the system maintains high measurement precision while reducing the dimensionality and processing requirements of the complete dataset.
Solution Approach 2:
The patent collects more measurement data than strictly necessary (excessive action) to ensure sufficient information is available for accurate characterization, then uses processing techniques to manage the resulting data volume. This approach ensures measurement precision is not compromised while allowing flexible processing strategies to manage time requirements.
Data Source
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AI summary
A system and a method for improving process yield and quality while reducing dependence on operator skill by automatically adjusting I.S. machine timing and motions. Container pixel data information (36) indicative of certain measurements of hot glass containers (32) manufactured by the I.S. machine obtained with a multipoint, multispectral glass container measurement system is mathematically transformed into a reduced dimensional measured signature (40). Event timing signals (58) to operate the cavities of the section of the I.S. machine in response to the measured signature (40) and a preferred target signature (46) are produced to automatically adjust the event timing of operations in the cavities of the section of the I.S. machine to diminish variations in the measured signature (40).