Preform Tempering Control Using Layer Temperature Models
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for temperature control of preforms in blow molding are imprecise and time-consuming, particularly when adjustments are needed during operation, leading to inefficient and potentially damaging heating processes.
Innovation Solution
A method using a preform model and temperature control device model to determine setting parameters for precise temperature conditioning, allowing adjustments during operation, ensuring temperatures remain within predefined limits to prevent material degradation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If experimental adjustment methods are used to set heating power, then temperature control can be achieved, but the process becomes very time-consuming and imprecise
Solution Approach 1:
The patent creates digital models (preform model and temperature control device model) in advance that capture the thermal behavior and heating characteristics. These models are used to pre-calculate optimal heating power settings for different scenarios, eliminating the need for time-consuming experimental adjustments during actual operation.
Solution Approach 2:
The patent creates digital copies (models) of the physical system - a preform model representing the preform's thermal properties and a temperature control device model representing the heating section's behavior. These digital models allow virtual experimentation and parameter optimization without affecting the physical system, providing precise predictions for actual temperature control.
2Adaptability or versatility
If manual experimental adjustment of heating boxes is performed, then temperature settings can be determined, but the method cannot be used during operation of the temperature control device
Solution Approach 1:
The patent replaces manual mechanical adjustment of heating boxes with an automated computer-based system. The control computer uses the digital models to automatically calculate and adjust heating power settings, enabling rapid reconfiguration during operation without manual intervention or production downtime.
Solution Approach 2:
The digital models are created in advance to capture system behavior, enabling the control computer to predict temperature outcomes and automatically adjust settings during operation. This preliminary modeling action enables real-time adaptability without requiring shutdowns for adjustment.
3Manufacturing precision
If uniform heating power is applied to all heating modules, then the system is simple to operate, but the temperature distribution across preform layers may not be optimized
Solution Approach 1:
The patent applies different heating power settings to different heating modules based on their specific positions and the local thermal requirements of the preform. The digital models enable calculation of position-specific optimal power settings, ensuring each heating module contributes optimally to the overall temperature distribution across all preform layers.
Solution Approach 2:
The patent changes the heating power parameter for each heating module based on calculations from the digital models. Instead of uniform power settings, the system dynamically adjusts power levels for different modules to achieve optimal temperature distribution, with the control computer managing the complexity of multiple parameter adjustments.
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
Enables efficient and precise temperature control of preforms, ensuring all layers reach suitable temperatures without exceeding maximum limits, facilitating smooth forming processes and preventing material damage.
Implementation Method 1
The preform model describes a temperature profile in each of several radial layers of a wall of the preform as a function of at least one heat input
Implementation Method 2
Several heating modules, in particular infrared emitters, are arranged along the conveying area
Data Source
Figure 1~2b
Figure 2c~3
Figure 4
AI summary
The invention relates to a method for operating a temperature control device (12), comprising determining setting parameters (28) with a controller (14) for the temperature control device (12) for temperature conditioning preforms (42) made of a thermoplastic material in a conveying area (38) of the temperature control device (12), wherein the preforms (42) are prepared for a subsequent forming process by temperature conditioning in the temperature control device (12), wherein several heating modules (30) are arranged along the conveying area (38) of the temperature control device (12). To determine the setting parameters (28), the controller (14) retrieves a preform model (18) that corresponds to a model of a preform (42).wherein the preform model (18) describes a temporal temperature profile in each of several radially defined layers of a wall of the preform (42) as a function of at least one temporal heat power profile entered into at least one of the layers, a retrieval of a temperature control device model (20) corresponding to a model of the temperature control device (12), wherein the temperature control device model (20) describes the temporal heat power profile that can be entered into at least one layer in the conveying area (38) defined by the temperature control device model (20) as a function of the setting parameters (28) for the heating modules (30), which correspond to the heating power parameters (34),The invention comprises specifying a maximum temperature (24) and/or a predefined temperature range (26) and determining the setting parameters (28) with which the temperature control device model (20) can determine at least one heat output profile over time, with which the preform model (18) can determine temperatures of all temperature profiles (76a, 76b, 76c, 76d), at least at a predefined point in time of the temperature profiles (76a, 76b, 76c, 76d), which lie below the maximum temperature and/or within the predefined temperature range (26). The invention further relates to a control unit for determining setting parameters (28) for a temperature control device (12), a system comprising a control unit and a temperature control device (12), and a computer program product.