Master-Slave Synchronization for Container Processing Machines
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Solution Overview
Problem
Existing synchronization solutions for container-processing machines in bottling plants require a significant amount of time to re-establish synchronization after faults occur, as they need to slow down and ramp up to full operating speed, which disrupts production efficiency.
Innovation Solution
Implementing a synchronization system where the filling machine can synchronize with the blowing machine at any speed, from zero to full processing speed, using a position sensor and a master/slave control unit communication, allowing independent operation and synchronization modes, enabling faster restarts and reduced downtime.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional synchronization methods using optical sensors and toothed wheels are used, then synchronization can be achieved, but the synchronization time is excessively long (up to 100 seconds or more) after faults occur
Solution Approach 1:
The patent replaces the mechanical/optical synchronization system (toothed wheels and optical sensors) with an electronic communication-based system. The master control unit transmits synchronization signals directly to the slave control unit via communication interfaces, eliminating the need for mechanical coupling and optical detection, thereby dramatically reducing synchronization time after faults.
Solution Approach 2:
The patent introduces a communication interface as an intermediary between the master and slave control units. This intermediary transmits synchronization signals electronically, replacing the direct mechanical/optical coupling method and enabling faster signal transmission and synchronization establishment.
2Reliability
If the machine slows down to synchronization speed for re-synchronization after faults, then synchronization can be re-established, but production throughput is significantly reduced
Solution Approach 1:
By replacing the mechanical speed-matching requirement with electronic signal transmission, the system can establish synchronization instantly without requiring the slave machine to slow down to a synchronization speed. The slave control unit receives synchronization signals from the master control unit and adjusts its operation accordingly, maintaining full production throughput.
3Reliability
If the existing synchronization system with multiple components (sensing wheels, optical sensors, pulse-train signals) is used, then synchronization can be achieved, but the system complexity increases
Solution Approach 1:
The patent extracts and removes the complex mechanical/optical synchronization components (toothed sensing wheels, optical sensors, pulse-train generation mechanisms) from the system. Only the essential synchronization function remains, implemented through simple electronic signal transmission between control units, thereby significantly reducing system complexity.
Solution Approach 2:
The patent substitutes the complex mechanical/optical synchronization subsystem with a simplified electronic communication-based synchronization mechanism. The master control unit directly transmits synchronization signals to the slave control unit, eliminating multiple intermediate components and simplifying the overall system architecture.
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 significantly reduces synchronization time, saving up to 100 seconds or more compared to traditional methods, thereby improving production throughput and efficiency, especially during fault recovery.
Implementation Method 1
a respective synchronization optical sensor 11, in particular a photocell sensor, operatively coupled to the sensing wheel 10
Data Source
Figure 1
Figure 2
Figure 3~5
AI summary
A synchronization system, for a container-processing plant (20) with a container-forming machine (22) and a container-filling machine (24) operatively coupled to the container-forming machine (22), the container-forming machine (22) and the container-filling machine (24) having a respective rotating wheel or carousel (25, 35) driven around a respective rotation axis (A, V) by a respective electric motor (26, 36) controlled by a respective control unit (28, 38); a position sensor (34) is provided in the container-forming machine (22) to measure a rotating position of its rotating wheel (25) around the respective rotation axis (A) and generate a position detection signal (S); the control unit (38) of the container-filling machine (24) receives information associated to the position detection signal (S), and, based on these information, synchronizes rotation of the respective rotating wheel (35) to the rotation of the rotating wheel (25) of the container-forming machine (22). The control unit (38) of the container-filling machine (24) synchronizes the rotation of the container-forming machine (22) and container-filling machine (24) at any speed, from, and including, zero speed, up to a full operating speed, i.e. a high speed at which processing, formation or filling, operations are designed to be performed.