Linear Preform Delivery for High-Throughput Container Blowing
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Solution Overview
Problem
Existing two-stage blowers for producing plastic containers face limitations in productivity and complexity, with rotary blowers being limited by carousel rotation speed and linear blowers having inconsistent heating times and lower productivity due to group transfers and complex mechanical designs.
Innovation Solution
A method and system that minimizes rotating masses by using a linear delivery system with fixed blowing stations and simultaneous heating, allowing for flexible preform delivery and optimized blowing cycles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a rotary blower with carousel is used, then blowing time consistency and product quality are improved, but hourly production is restricted by rotation speed and construction cost increases
Solution Approach 1:
The system divides the blowing process into multiple independent blowing stations (first blowing station, second blowing station, etc.) arranged along a linear path. Each station operates independently to blow preforms, eliminating the single-point bottleneck of rotary blowers while maintaining consistent blowing times through synchronized control of each station.
Solution Approach 2:
The patent replaces the rotary mechanical carousel system with a linear reciprocating movement system. The movement system moves preforms linearly through fixed blowing stations rather than rotating the entire carousel, reducing mechanical complexity and allowing higher speeds without the centrifugal forces and synchronization issues of rotary systems.
2Device complexity
If a linear blower with single mould is used, then device complexity is reduced, but hourly productivity decreases due to slower movement and group transfers
Solution Approach 1:
The system segments the blowing function across multiple fixed stations rather than using a single moving mould. Each blowing station remains stationary while the preform moves through them, simplifying each individual station's mechanics while increasing overall capacity through parallel processing at multiple stations.
Solution Approach 2:
The patent introduces dynamic control of the reciprocating movement system to optimize the timing and speed of preform transfer between stations. The system dynamically adjusts the movement cycle to synchronize with the blowing process at each station, maximizing throughput while maintaining simplicity in the mechanical design of each station.
3Device complexity
If linear blower group transfer is used, then device complexity is reduced, but heating time uniformity deteriorates due to variable waiting times
Solution Approach 1:
The system implements preliminary positioning of preforms at regular intervals along the linear path before they enter the heating zone. The reciprocating movement system is synchronized to pick up preforms at precise intervals, ensuring that each preform spends the same amount of time in the heating zone regardless of when it was loaded, thereby uniformizing heating time.
Solution Approach 2:
The control system monitors the position and timing of preform transfer and adjusts the reciprocating movement cycle to maintain consistent heating times. Feedback from sensors detecting preform positions allows real-time synchronization of the movement system with the heating process, ensuring uniformity despite variations in loading rates.
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
Enhances productivity and reduces complexity by ensuring uniform heating and consistent blowing times, minimizing rotating masses, and simplifying mechanical and maintenance costs.
Implementation Method 1
By exploiting the thermoplastic characteristics of the polymer of which it is composed, the preform is subjected to a heating process, using ovens
Implementation Method 2
The preform is loaded onto a spindle chain and, crossing a series of infra-red ray ovens, it is brought to a suitable temperature for blowing
Implementation Method 3
inside the mould, the preform is mechanically stretched, using a rod
Implementation Method 4
simultaneously subjected to a high pressure air flow. Adhering to the walls of the mould the material assumes the shape
Data Source
AI summary
A system for producing plastic containers from preforms, comprising: a plurality of blowing stations comprising at least a first and a second blowing station (31, 32) for blowing the preforms; a movement system (2) for moving the preforms comprising a delivery line (21) for delivering the preforms towards said blowing stations. The delivery line (21) comprises a first and a second outlet zone (211, 212) of the preforms from said delivery line (21). The first and the second outlet zone (211, 212) for the outlet of the preforms are in mutually distinct positions and are intended to supply the first blowing station (31) and the second blowing station (32), respectively.