Robot for Container Plant Tool Changes
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Solution Overview
Problem
Existing manufacturing installations for thermoplastic containers require lengthy and costly manual operations for changing molds and tools, leading to prolonged downtime and inefficiency.
Innovation Solution
The integration of a robot that can selectively intervene on both thermal conditioning and shaping units, automating operations such as tool changes and maintenance, while maintaining the installation's compactness and ensuring controlled access and air quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual operations are used for changing molds and tools, then the installation can be operated, but the downtime is prolonged and costs increase
Solution Approach 1:
The robot system performs maintenance operations and tool changes autonomously without requiring human operators to stop the production line. The robot navigates to the thermal conditioning unit, opens access doors, removes old molds, and installs new ones automatically, enabling the system to service itself during operation.
Solution Approach 2:
Manual mechanical operations for mold changing and maintenance are replaced with an automated robotic system. The robot uses end-effectors to grip and manipulate molds, and coordinate control systems to orchestrate the complex sequence of door opening, mold removal, and installation operations, eliminating the need for manual intervention.
2Extent of automation
If a robot is positioned to intervene on multiple units, then automation is achieved, but the installation complexity increases
Solution Approach 1:
A single robot system is designed to perform multiple functions across different units. The same robot can intervene on both the thermal conditioning unit and the shaping unit, performing various operations including mold changes, maintenance tasks, and inspections. This multi-functional approach reduces the need for multiple specialized robots while achieving comprehensive automation.
Solution Approach 2:
The robot acts as an intermediary between the control system and the physical units. It receives commands from the control system, navigates to the appropriate unit, performs the required operation using its end-effectors, and reports back to the control system. This intermediary role simplifies the overall control architecture by centralizing the automation intelligence in the robot's control system.
3Ease of operation
If access doors are opened for robot intervention, then the robot can perform operations, but air quality control becomes more difficult
Solution Approach 1:
Access doors are opened only periodically when maintenance or tool changes are required, rather than remaining open continuously. The control system monitors the operational state and triggers door opening only when the robot needs to intervene, minimizing the duration of exposure and maintaining air quality during normal operation.
Solution Approach 2:
The robot performs maintenance operations quickly and efficiently, minimizing the time that access doors remain open. The automated nature of the robot allows it to complete mold changes and maintenance tasks faster than manual operations, reducing the duration of air quality compromise and enabling rapid return to normal production.
Data Source
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AI summary
The invention relates to a plant (10) for manufacturing containers (12) from thermoplastic preforms (16), said plant (10) comprising at least: - a first unit (12) for thermally conditioning the preforms (16) which comprises a first vertical lateral face (F1); and - a second unit (14) for shaping the containers (24) from said preforms (16) which have been thermally conditioned in the first unit (12), said second unit comprising a second vertical lateral face (F2); characterized in that the plant (10) comprises at least one robot (50) which faces the first vertical lateral face (F1) and the second vertical lateral face (F2) in order to selectively operate through the first vertical lateral face (F1) and/or through the second vertical lateral face (F2) to carry out operations on the first unit (12) and/or the second unit (14).