Resin Preform Conveyance Abnormality Detection for High-Speed Blow Molding
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Solution Overview
Problem
In high-speed molding processes for resin containers, setting appropriate threshold values for operation abnormality detection is challenging, relying heavily on operator skill and varying with molded product conditions, leading to increased risk of mold or machine damage.
Innovation Solution
An operation abnormality detection method using statistical calculations to set threshold values based on average values and standard deviations, with adjustable parameters, to detect and warn of abnormal operations in molding apparatuses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high-speed molding is implemented to increase productivity, then output per time is improved, but the risk of damage to mold or machine increases remarkably due to reduced stability of movable parts
Solution Approach 1:
The patent implements a feedback mechanism where sensor data from the movable part is continuously monitored and fed back to the control unit. The control unit compares actual operation data with reference data to detect abnormalities, enabling real-time adjustments to maintain stable operation during high-speed molding cycles.
Solution Approach 2:
The system performs self-diagnosis by automatically monitoring its own operational parameters through embedded sensors and control logic. The movable part's health status is assessed autonomously without external intervention, allowing the system to identify and respond to potential failures before they cause damage.
2Measurement precision
If threshold values are set manually by skilled workers based on molding conditions, then detection accuracy is improved, but the workload and complexity of setup is increased
Solution Approach 1:
The control unit automatically generates threshold values by analyzing reference data collected during normal operation. This self-configuring capability eliminates the need for manual threshold setting by skilled workers, reducing setup complexity while maintaining detection accuracy through data-driven threshold determination.
Solution Approach 2:
The system performs preliminary data collection during normal operation to establish reference patterns before abnormality detection begins. This preliminary action creates a baseline of normal operation characteristics that the system uses to automatically determine appropriate threshold values for anomaly detection.
3Measurement precision
If threshold values are set to be highly sensitive to detect early abnormalities, then detection capability is improved, but false alarms increase and reduce operational reliability
Solution Approach 1:
The control unit continuously monitors operation data and dynamically adjusts threshold values based on feedback from actual system behavior. This adaptive feedback mechanism allows the system to maintain high sensitivity for detecting true abnormalities while learning to distinguish them from normal operational variations, thereby reducing false alarms.
Solution Approach 2:
The threshold values are not fixed but dynamically adjusted based on actual operation conditions and historical data. This dynamic adaptation allows the system to maintain optimal detection sensitivity across varying operating conditions while minimizing false positive rates through context-aware threshold modification.
Data Source
AI summary
A manufacturing apparatus and method for a resin container. The apparatus includes at least: a heating unit configured to heat a preform; a blow molding part configured to mold a plurality of the preforms into a container; and a conveyance member configured to convey the plurality of preforms that has been heated to the blow molding part. The conveyance member includes: a plurality of holding arms each configured to hold one of the plurality of preforms; a connecting member configured to connect together the plurality of holding arms at equal intervals; and a pitch changing mechanism configured to change a pitch between the plurality of holding arms, and the pitch changing mechanism includes a stopper mechanism configured to position the plurality of holding arms at a predetermined wide pitch when an interval of the holding arms is changed from a narrow pitch to the predetermined wide pitch.