Robotic Blank Mold Replacement in Hollow Glass Manufacturing
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Solution Overview
Problem
The existing manufacturing process of hollow glass products faces issues with surface defects due to violent contact between the parison and the blank mold, requiring frequent greasing and eventual replacement of molds, which is labor-intensive, causes operator strain, and occurs in a harsh environment.
Innovation Solution
A robotic system is introduced to replace and maintain blank molds on IS machines, equipped with an electromagnet, temperature measurement tools, cleaning tools, and imaging capabilities, allowing for automated greasing, cleaning, and defect detection, reducing manual labor and improving safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual replacement of blank molds is performed, then the operator can replace molds, but the operator experiences spinal strain, pain or lesions due to carrying heavy molds in a forwardly inclined position
Solution Approach 1:
The patent replaces the manual mechanical system with an automated robotic system. The robot is equipped with electromagnets that magnetically hold the blank molds, eliminating the need for operators to manually carry heavy molds. This substitution of mechanical human labor with an automated electromechanical system resolves the contradiction by removing the weight burden from the operator while maintaining the mold replacement function.
Solution Approach 2:
The robotic system performs the mold replacement operation autonomously without human intervention. The robot navigates to the molding machine, uses its electromagnets to grasp and replace molds, and returns to its starting position all automatically. This self-service capability eliminates operator exposure to the harmful working conditions while maintaining continuous production.
2Productivity
If manual replacement of blank molds is performed, then the operator can replace molds, but the replacement operation takes a significant amount of time causing production stoppage
Solution Approach 1:
The automated robotic system performs mold replacement much faster than manual operation. The robot can quickly position, attach, and replace molds using its electromagnets without the time-consuming manual handling, positioning, and safety procedures required for human operators. This dramatically reduces the loss of time during mold replacement and maintains production continuity.
Solution Approach 2:
The robot is pre-positioned alongside the molding machine and maintains readiness to perform replacements. The electromagnets are pre-configured to engage with the mold attachment points, allowing for rapid exchange operations. This preliminary preparation eliminates the time lag associated with manual tool preparation and positioning.
3Manufacturing precision
If the blank mold surface quality deteriorates, then the parison contact causes visible defects, but replacing the mold manually requires operator intervention in a noisy and high-temperature environment
Solution Approach 1:
The robotic system performs all mold replacement operations remotely, keeping operators out of the noisy and high-temperature environment near the molding machine. The robot endurance to harsh conditions allows continuous operation without operator exposure to harmful environmental factors while maintaining the ability to replace molds when surface quality deteriorates.
Solution Approach 2:
The robot autonomously monitors and responds to mold condition, performing replacements based on predetermined criteria without requiring operator assessment in the harsh environment. This self-service capability eliminates operator exposure to noise and heat while ensuring timely mold replacement to maintain surface quality.
4Manufacturing precision
If frequent greasing of blank molds is performed to eliminate surface defects, then surface quality improves, but the maintenance operation increases production downtime
Solution Approach 1:
The robotic system can perform greasing operations quickly and efficiently, maintaining continuous production flow. The robot applies lubrication to the mold surfaces as part of its automated maintenance routine without requiring production stoppage, ensuring continuous useful action while maintaining surface quality.
Solution Approach 2:
The robot performs self-maintenance of the molds by applying lubrication automatically during its operational cycles. This automated maintenance eliminates the need for manual intervention and minimizes production downtime while ensuring consistent surface quality through regular lubrication.
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
The robotic system significantly reduces downtime for mold replacement, minimizes operator strain, and enhances surface quality by enabling automated maintenance and defect correction, improving the efficiency and safety of the glass manufacturing process.
Implementation Method 1
the robot preferably carries an electromagnet, or as many electromagnets as there are blank molds in a section
Data Source
AI summary
A process for manufacturing a hollow glass product using an I.S. machine and a robot that can move alongside blank molds of the I.S. machine, wherein the robot is capable of replacing one or more blank molds, section after section. The I.S. machine for manufacturing hollow glass products includes a robot that can move alongside the blank molds, and the robot is capable of carrying plural tools having different functions, simultaneously and/or alternately, chosen from an electromagnet, and/or a spray tube for greasing by spraying, and/or an optical pyrometer, an infrared or equivalent viewing port, and/or a rotary abrasive tool, and/or a camera or equivalent.