Production Device Control Model for Consistent Product Quality
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Solution Overview
Problem
Existing methods for operating devices that produce products, such as molding hollow bodies or injection-molded parts, are inefficient and inaccurate due to the need for continuous manual adjustments and expert knowledge to maintain product quality.
Innovation Solution
A method that captures quality data records and machine data records, correlates them to create a control model, and sets target values for machine parameters to ensure consistent product quality, reducing the need for continuous testing and manual adjustments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If continuous testing of each individual product is performed to maintain product quality, then product quality consistency is improved, but production cost and complexity increase
Solution Approach 1:
The patent implements a feedback mechanism where measured quality parameters of produced items are continuously fed back to the control system. The control system compares actual quality parameters against target values and automatically adjusts machine parameters to maintain quality consistency, eliminating the need for complex continuous testing of each product.
Solution Approach 2:
The production system performs self-adjustment by automatically modifying machine parameters based on quality measurements. The control system autonomously compensates for deviations without requiring external intervention or complex testing procedures for each individual product.
2Manufacturing precision
If manual adjustment and readjustment of machine parameters is performed to maintain product quality, then product quality is improved, but production time and productivity decrease
Solution Approach 1:
The control system continuously receives feedback from quality measurements and automatically adjusts machine parameters in real-time, replacing manual adjustment processes. This maintains product quality while eliminating the time loss associated with manual intervention.
Solution Approach 2:
The patent replaces manual mechanical adjustment operations with an automated control system that electronically adjusts machine parameters. This substitution eliminates the time-consuming nature of manual adjustment while maintaining or improving quality consistency.
3Manufacturing precision
If expert knowledge is used to perform simulations and determine parameter changes, then product quality control is improved, but operational complexity and effort increase
Solution Approach 1:
The control system autonomously determines optimal parameter adjustments based on quality measurements and the control model, without requiring expert knowledge or manual simulation. The system self-manages the complex calculations and decision-making processes that would otherwise require specialized expertise.
Solution Approach 2:
The patent replaces expert-based manual simulation and judgment with an automated control algorithm that processes quality data and determines parameter adjustments. This substitution eliminates the need for expert knowledge while maintaining or improving control accuracy.
4Manufacturing precision
If device parameters are continuously monitored and adjusted to compensate for environmental and device changes, then product quality consistency is improved, but system complexity increases
Solution Approach 1:
The control system implements continuous monitoring of both quality parameters and machine parameters, creating a closed-loop feedback system. This automatically compensates for environmental and device changes without requiring complex manual intervention or increasing operational complexity.
Solution Approach 2:
The control system serves multiple functions simultaneously: it monitors quality parameters, compares them against target values, determines deviations, and adjusts machine parameters. This multi-functionality consolidates what would otherwise require separate complex systems into a single integrated solution.
Data Source
AI summary
A method for operating a device to produce a product includes capturing at least one quality data record that includes measured values of one or more quality parameters that each correspond to one property of the product. The method captures at least one associated machine data record including actual values of several adjustable machine parameters of the device, chronologically assigns the quality data record to the machine data record, and generates a first data record comprising chronologically-correlated measured values and actual values. The preceding steps are repeated at least once to generate at least one second data record. A correlation is determined between the quality parameter(s) and the machine parameter(s). The method provides a corresponding target value for at least one of the adjustable machine parameters on the basis of the control model, proceeding from a target value of the quality parameter(s).