Preform Temperature Control for Plastic Bottle Manufacturing
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Solution Overview
Problem
Existing plastic bottle manufacturing devices face challenges in maintaining consistent physical properties due to variations in preform storage conditions, environmental temperatures, and heater conditions, leading to inconsistencies in the shape and physical properties of molded bottles, and existing methods for correcting these issues require discarding large numbers of bottles and are not suitable for high-volume production.
Innovation Solution
A plastic bottle manufacturing device equipped with a preform heating part, a blow-molding part, and a preform temperature measuring part that measures temperatures at multiple points along the preform, with a control unit adjusting the heating outputs based on optimal and actual temperature distributions to maintain consistent preform temperatures, ensuring uniform bottle production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a preform-heating heater is controlled to realize a preset condition, then the same temperature and humidity conditions are maintained, but variations in storage conditions, environmental temperatures, and heater conditions cause the actual preform temperatures to deviate, leading to variations in bottle shape and physical properties
Solution Approach 1:
The patent implements a feedback control system where a temperature measurement device measures the actual temperature of preforms at multiple positions, and this measured temperature information is fed back to a control device that adjusts the heating device's output accordingly. This closed-loop feedback mechanism compensates for variations in storage conditions, environmental temperatures, and heater conditions, ensuring consistent preform temperatures and thereby maintaining reliable bottle physical properties.
Solution Approach 2:
The patent replaces manual or simple mechanical temperature control with an automated control system that uses temperature measurement devices and control devices to automatically adjust heating parameters. This substitution of mechanical control with automated sensing and control systems enables precise temperature management, eliminating the precision issues caused by manual adjustment and environmental variations.
2Manufacturing precision
If wall thickness measurement and feedback is performed for one bottle at a time, then data can be obtained for heater adjustment, but a large number of bottles must be discarded and time is lost, making it unsuitable for high-volume production
Solution Approach 1:
The patent performs temperature measurement and control adjustments on preforms before they are molded into bottles. By measuring preform temperatures and adjusting heating parameters in advance, the system ensures that all subsequent bottles are produced under optimal conditions without needing to discard bottles for measurement and adjustment. This preliminary action eliminates the need for post-molding measurement and bottle discarding, maintaining both precision and productivity.
Solution Approach 2:
The system uses the preforms themselves as the objects of measurement and control, rather than requiring finished bottles to be measured. The temperature measurement devices measure preform temperatures directly, and the control device adjusts heating based on this information, allowing the process to self-regulate without external intervention or waste of production materials.
3Manufacturing precision
If multiple heating bodies are used in the longitudinal direction of the preform, then temperature distribution can be controlled, but the device complexity increases
Solution Approach 1:
The heating system is segmented into multiple independent heating bodies positioned at different locations along the longitudinal direction of the preform. Each heating body can be independently controlled based on temperature measurements at corresponding positions, allowing precise control of temperature distribution across different sections of the preform. This segmentation enables localized temperature adjustment without requiring a completely complex system redesign.
Solution Approach 2:
Different heating bodies are controlled to provide different temperature levels at different longitudinal positions of the preform, creating a tailored temperature distribution that matches the specific heating requirements of each section. This local quality approach ensures that each part of the preform receives the appropriate temperature treatment, improving overall manufacturing precision while justifying the increased device complexity through targeted functionality.
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 effectively suppresses variations in plastic bottle physical properties by precisely controlling preform temperatures, reducing the need for extensive bottle discarding and enabling consistent production across varying conditions, thus maintaining quality and efficiency in high-volume manufacturing.
Implementation Method 1
a preform heating part that heats a preform
Implementation Method 2
the preform temperature measuring part may be a thermography
Data Source
AI summary
A plastic bottle manufacturing device (50) includes a preform heating part (52) that includes a plurality of heating bodies (65), a blow-molding part (54) that molds a plastic bottle (20) by blow-molding a preform (10), and a preform temperature measuring part (53) that measures temperatures of the preform (10) at a plurality of measurement points (P) in a longitudinal direction of the preform (10). The plurality of measurement points (P) are provided in correspondence with the plurality of heating bodies (65). A control unit (70) controls an output of each heating body (65) based on an optimal temperature distribution at each measurement point (P) of the preform (10) that has been predetermined and an actually measured temperature distribution at each measurement point (P) of the preform (10).