Blow Molding Preform Temperature Control via Voltage Fluctuation Feedback
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Solution Overview
Problem
Conventional blow-molding apparatuses face challenges in maintaining uniform preform temperature distribution due to voltage fluctuations in the supply power source, leading to increased defects such as preform rupture and non-uniform container quality, especially during high-cycle operations.
Innovation Solution
A blow-molding apparatus equipped with a monitoring device to constantly monitor voltage fluctuations and an automatic output control mechanism that adjusts the heating and cooling devices to maintain preform and ambient temperatures within a normal range, ensuring consistent temperature distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If voltage fluctuation is not compensated, then the heating and cooling device outputs fluctuate, but this causes non-uniform temperature distribution and preform rupture
Solution Approach 1:
The patent implements a feedback control system where a monitoring device continuously detects voltage fluctuations and sends signals to the output automatic control mechanism. This mechanism adjusts the power supply to heating and cooling devices based on the detected voltage variations, creating a closed-loop feedback system that maintains stable temperature distribution despite external voltage fluctuations.
Solution Approach 2:
The patent introduces an intermediary control system consisting of a monitoring device and an output automatic control mechanism that acts as a mediator between the unstable power source and the temperature-sensitive heating/cooling devices. This intermediary layer filters out voltage fluctuations before they reach the thermal processing equipment, protecting the temperature uniformity.
2Productivity
If high-cycle operation is performed, then productivity increases, but temperature control stability deteriorates
Solution Approach 1:
The patent ensures continuous temperature control by implementing a monitoring device that operates continuously during high-cycle production. The output automatic control mechanism continuously adjusts power delivery to heating and cooling devices, maintaining uninterrupted and stable temperature management even during rapid successive molding cycles.
Solution Approach 2:
The patent employs dynamic control by making the output of heating and cooling devices adjustable in real-time based on actual voltage conditions. The output automatic control mechanism dynamically modifies power delivery parameters according to monitored voltage fluctuations, enabling the system to adapt to changing electrical conditions during high-speed operation.
3Use of energy by moving object
If infrared heater output decreases due to voltage fluctuation, then energy consumption decreases, but preform temperature becomes insufficient and distribution becomes non-uniform
Solution Approach 1:
The patent changes the operational parameters of the infrared heater by automatically adjusting its power output based on detected voltage fluctuations. When voltage drops, the control mechanism increases current or duty cycle to maintain heating effectiveness; when voltage rises, it reduces power to prevent overheating. This dynamic parameter adjustment maintains temperature uniformity while optimizing energy consumption.
Solution Approach 2:
The system uses feedback control where the monitoring device detects voltage changes and the output automatic control mechanism responds by adjusting heater power levels. This closed-loop control ensures the preform receives consistent thermal energy regardless of voltage fluctuations, maintaining uniform temperature distribution while avoiding energy waste from excessive heating.
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 reduces the occurrence of defects like preform rupture and enhances the quality of blow-molded containers by maintaining uniform temperature distribution, even under fluctuating voltage conditions.
Implementation Method 1
a heating device configured to heat an injection-molded preform to increase a preform temperature or an ambient temperature thereof... the heating device... heats the preform passing through the device by, for example, an infrared heater
Implementation Method 2
cooling air is blown from a blower which is the cooling device to the preform to cool the preform... a blower which is the cooling device to cool the preform
Data Source
AI summary
In a blow-molding apparatus, a cooling device and a heating device are each driven by being supplied with electricity of a predetermined voltage from a supply power source. The blow-molding apparatus comprises: a monitoring device configured to constantly monitor fluctuation of the predetermined voltage; and an output automatic control mechanism configured to, in a case where the predetermined voltage monitored by the monitoring device fluctuates beyond a normal range, automatically fluctuate an output of at least one of the heating device and the cooling device to keep the output in a certain range, thereby adjusting at least one of the preform temperature and the ambient temperature to fall within a normal temperature range.