Multi-Module Machine Start-Up with Synchronized Speed Ramping

Solution Overview

Problem

Conventional methods for starting a machine with multiple modules for manufacturing plastic containers result in uneven start-up times, leading to premature fatigue, increased energy consumption, and mechanical stress due to abrupt acceleration, which can cause module deterioration and reduce lifespan.

Innovation Solution

A method that identifies the slowest module and synchronizes the start-up of other modules to reach optimal operating conditions at the same time, using specific ramp-up durations for each module to reduce energy consumption and wear, and considers production and climatic parameters for adaptive start-up.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If all modules are started at the same time to reduce overall start-up time, then productivity is improved, but modules with shorter ramp-up times experience premature fatigue and increased energy consumption

Engineering Contradiction:

Improvestart-up timeVSAvoidmodule fatigue

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The system performs preliminary identification of the slowest module before starting the synchronized ramp-up sequence. By knowing which module has the longest ramp-up time in advance, the control system can coordinate all modules to start simultaneously and reach optimal conditions at the same time, preventing premature fatigue of faster modules.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system continuously monitors the ramp-up status of each module and adjusts their operation accordingly. The control system receives feedback from each module about its current state and uses this information to maintain synchronized operation, ensuring that all modules reach optimal conditions simultaneously without over-stressing any individual module.

Inventive Principle:

Principle #23Feedback

2Productivity

If modules are started abruptly to reduce start-up time, then productivity is improved, but mechanical stress increases causing module deterioration

Engineering Contradiction:

Improvestart-up timeVSAvoidmechanical stress

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The system performs preliminary identification of the slowest module before starting the synchronized ramp-up sequence. By knowing which module has the longest ramp-up time in advance, the control system can coordinate all modules to start simultaneously and reach optimal conditions at the same time, preventing premature fatigue of faster modules.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system continuously monitors the ramp-up status of each module and adjusts their operation accordingly. The control system receives feedback from each module about its current state and uses this information to maintain synchronized operation, ensuring that all modules reach optimal conditions simultaneously without over-stressing any individual module.

Inventive Principle:

Principle #23Feedback

3Reliability

If modules operate in idle mode while waiting for the slowest module, then synchronization is achieved, but energy consumption increases

Engineering Contradiction:

Improvesynchronized operationVSAvoidenergy consumption

Core Design Contradiction:

ReliabilityVSUse of energy by stationary object

Solution Approach 1:

The system performs preliminary identification of the slowest module before starting the synchronized ramp-up sequence. By knowing which module has the longest ramp-up time in advance, the control system can coordinate all modules to start simultaneously and reach optimal conditions at the same time, preventing premature fatigue of faster modules.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system continuously monitors the ramp-up status of each module and adjusts their operation accordingly. The control system receives feedback from each module about its current state and uses this information to maintain synchronized operation, ensuring that all modules reach optimal conditions simultaneously without over-stressing any individual module.

Inventive Principle:

Principle #23Feedback

Data Source

PatentEP4038460B1Start-up method for multi-module machine

Publication Date: 2024.07.31 SIDEL PARTICIPATIONS SAS

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AI summary

The invention concerns a method for starting up a machine (1) comprising a plurality of modules (6), each module (6) having a standard duration for which operating speed increases until optimum operating conditions are reached, characterised in that the method comprises the steps: - for each module (6), acquiring an initial operating speed state at an instant T0 and a duration for which operating speed increases in order for the optimum operating conditions to be reached, starting from instant T0; - identifying a slow module (6) having the longest operating speed increase duration and determining an instant T1 of optimum operation, at the end of the increase in operating speed, when the slow module (6) has its optimum operating conditions; - and, for each module (6) apart from the slow module (6), establishing a setpoint for the start or duration of the operating speed increase, for which setpoint its optimum operating conditions are reached only at instant T1 or very close to instant T1.