Pre-Blow Fluid Flow Control for Precise Container Expansion
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Solution Overview
Problem
Existing blow molding technologies require time-consuming and material-specific setpoint value profiles for controlling blow molding fluid flow, which are inflexible and unable to adapt to variations in material characteristics or equipment wear, leading to inefficient container production.
Innovation Solution
A control device with a proportional valve, actuator, pressure sensors, and a digital control system that calculates control values in real-time to achieve a predefined container volume during the pre-blow molding phase, allowing for adaptive and precise control of blow molding fluid flow without predefining a setpoint value profile, and compensating for disturbance variables.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If time-consuming and material-specific setpoint value profiles are used for controlling blow molding fluid flow, then manufacturing precision can be maintained, but productivity decreases and adaptability is reduced
Solution Approach 1:
The patent implements a feedback control system where the actual container volume is measured during the pre-blow molding phase and compared to the target volume. The control device automatically adjusts the blow molding fluid flow rate based on the volume deviation, eliminating the need for pre-defined setpoint profiles while maintaining precision. This real-time feedback loop enables both high productivity and manufacturing precision simultaneously.
Solution Approach 2:
The control system transitions from static, pre-defined setpoint profiles to dynamic, real-time control. The blow molding fluid flow is continuously adjusted during the molding process based on actual container volume measurements, allowing the system to adapt to material variations and equipment wear without reducing production speed or precision.
2Stability of the object's composition
If fixed setpoint value profiles are used for blow molding control, then manufacturing stability is maintained, but adaptability to material variations and equipment wear is lost
Solution Approach 1:
The feedback control system continuously monitors actual container volume and adjusts blow molding fluid flow in real-time, enabling the process to adapt to material variations and equipment wear while maintaining stable production. The system self-corrects deviations without requiring manual intervention or reprogramming.
Solution Approach 2:
The control system performs self-adjustment based on real-time measurements, eliminating the need for external calibration or reprogramming when material or equipment conditions change. The system automatically compensates for disturbances, maintaining process stability through autonomous adaptation.
3Manufacturing precision
If complex pre-defined control profiles are implemented, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The patent replaces complex pre-defined control profiles with a simple feedback control mechanism that measures actual container volume and adjusts blow molding fluid flow accordingly. This approach achieves high manufacturing precision through a relatively simple control structure that relies on real-time measurement and adjustment rather than complex pre-programmed sequences.
4Productivity
If real-time adaptive control is implemented, then productivity and flexibility are improved, but measurement and control complexity increases
Solution Approach 1:
The patent implements real-time container volume measurement using appropriate sensors and feeds this information back to the control device, which adjusts blow molding fluid flow accordingly. This feedback mechanism enables productive real-time adaptation while managing measurement complexity through established sensing and control techniques.
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 solution enables efficient, adaptive control of container growth and expansion in the pre-blow molding phase, simplifying parameterization and improving production flexibility by automatically adjusting to material and equipment variations, allowing for simultaneous production of different container forms and material mixtures.
Implementation Method 1
a proportional valve (2) having a modifiable throughflow cross section... calculating, in a manner automated to the run-time, control values for actuating the actuator for the attainment of a predefined container volume
Implementation Method 2
sensor means for detecting the valve inlet pressure and valve outlet pressure... with consideration to the container volume attained up to the respective calculation cycle and calculatable by way of the previous actuator positions and the previous pressure course
Data Source
AI summary
The disclosure relates to a device and a method for controlling the throughflow of blow-molding fluid during the blow molding of containers. It is the intention to provide a control device and a control method which permit a controlled or defined growth and a defined propagation of the container bubble formed by the expanding preform in the pre-blowing phase of the blow molding process without the specification of a specific setpoint value profile or of a setpoint value curve. The object is achieved by means of a control device and a control method having a proportional valve with a variable throughflow cross section, having an actuator for the operation of the proportional valve, having a means for detecting the position of the actuator, and having sensor means for detecting the valve inlet and valve outlet pressure, wherein a time for the attainment of the yield point for the preform, a container volume and a time period for the attainment of the container volume are predefinable, and, by means of a digital controller, during the pre-blowing phase, from the attainment of the yield point until the run duration, a calculation of control values for the operation of the actuator in order to attain the predefined container volume within the predefined time period is performed in automated cyclic fashion, and the actuator is operated in accordance with the calculated control values, wherein, in each calculation cycle, the calculation of the respectively next control value is performed taking into consideration the container volume attained prior to the respective calculation cycle and calculated on the basis of the previous actuator positions and the previous pressure profile.