IS Machine Valve Timing Control for Glass Container Defects
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Solution Overview
Problem
The existing operation of IS machines for producing glass containers faces challenges in ensuring that the timing of vacuum and blowing pressures aligns correctly, leading to increased deformation rates and pressure cracks, which are difficult to control due to factors like electronic timer hysteresis and valve conditions, resulting in rejected glass containers.
Innovation Solution
The solution involves measuring the courses of vacuum and blowing pressures and checking if they meet predetermined conditions, allowing for adjustments in the timing of valve activations to maintain optimal pressure relationships, issuing warnings or sorting out defective containers based on pressure peak differences and maximum pressure thresholds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the timing of vacuum and blowing pressures is controlled using electronic timer with fixed time difference, then the processing speed is increased, but the timing accuracy deteriorates due to switching hysteresis and valve conditions
Solution Approach 1:
The patent applies feedback by continuously monitoring the actual vacuum pressure and blowing pressure values and comparing them against target profiles. The control system adjusts the timing of pressure application based on real-time measurements, compensating for variations in valve response times and electronic timer hysteresis. This closed-loop control ensures that the actual pressure timing matches the desired timing despite component variations.
Solution Approach 2:
The patent transitions from static, pre-programmed timing to dynamic, adaptive timing control. The control system continuously adjusts the timing parameters based on real-time pressure measurements and actual process conditions. This allows the system to adapt to changing valve conditions, temperature variations, and other dynamic factors that affect pressure application timing.
2Reliability
If the timing of final blowing and vacuum is set with time difference to prevent pressure cracks, then the occurrence of pressure cracks is reduced, but the processing time increases
Solution Approach 1:
The patent applies partial action by implementing minimum necessary time delays only where needed to prevent pressure cracks, rather than applying uniform time delays to all pressure transitions. The control system optimizes the timing to provide just enough separation between vacuum and blowing pressures to prevent defects while minimizing the impact on overall cycle time.
Solution Approach 2:
The patent dynamically adjusts timing parameters based on real-time pressure measurements and process conditions. By monitoring actual pressure build-up rates and glass deformation behavior, the control system optimizes the time difference between vacuum and blowing application, reducing it when safe and increasing it only when necessary to prevent pressure cracks.
3Productivity
If the pressures for final blowing and vacuum generation are applied at the same time, then the processing speed is maximized, but pressure cracks occur due to increased deformation rate
Solution Approach 1:
The patent applies preliminary action by preparing the glass container wall in advance through controlled vacuum application before introducing blowing pressure. The system monitors the glass deformation rate and ensures the wall is properly prepared and stabilized before the blowing pressure is applied, preventing sudden stress concentrations that could cause pressure cracks.
Solution Approach 2:
The patent implements cushioning by applying vacuum pressure beforehand to stabilize the glass container wall and reduce its deformation rate before blowing pressure is introduced. This preliminary stabilization creates a more favorable stress state that reduces the risk of pressure cracks when the blowing pressure is subsequently applied.
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 the reject rate of glass containers by ensuring that the pressures are applied in a controlled manner, minimizing deformation and pressure cracks, and optimizing the production process to maintain desired pressure gradients and build-up times.
Implementation Method 1
controlling a vacuum valve (4) to create a vacuum in the finished mold (3)
Implementation Method 2
controlling a final blowing valve (6) to create a final blowing pressure from a second control time, which is a predetermined period of time later than the first control time, so that compressed air is blown into the finished mold (3) from above
Data Source
Figure 1~8
Figure 2~3
Figure 4a~5b
AI summary
The invention relates to a method for operating an IS machine (1) for the production of glass containers, wherein the IS machine (1) has a plurality of preforms (2) and a plurality of finished molds (3), and each preform (2) interacts with a finished mold (3), comprising the following process steps, which are carried out for each pair of a preform (2) and a finished mold (3): introducing a drop of glass into the preform (2), generating a flask from the drop of glass in the preform (2), transferring the flask into the finished mold (3), actuating a vacuum valve (4) to generate a vacuum in the finished mold (3) from a first actuation point and simultaneously measuring the vacuum pressure profile, actuating a final blowing valve (6) to generate a final blowing pressure from a second actuation point, which is a predetermined time later than the first actuation point, so that compressed air is blown into the finished mold from above.and simultaneous measurement of the finished blowing pressure curve and verification of whether the measured vacuum pressure curve and/or the measured finished blowing pressure curve have met a predetermined condition. This provides a means of enabling the operation of an IS machine in which rejects due to defectively manufactured glass containers can be easily detected and which, in addition, preferably has only a low reject rate of glass containers.