Interactive Control Program Generation for Rotary Bottle Coating Machines
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Solution Overview
Problem
Existing programming tools for rotary machines, particularly those with PLC and microcontrollers, are complex and user-unfriendly, requiring manual programming that is unreasonable for non-developers and do not account for the specific needs of users, as they primarily focus on reusing components and are directed towards developers.
Innovation Solution
A device and method that uses an interactive input system with a structured menu guidance to generate control programs for rotary machines, allowing users to create program codes for controlling processing stations and components through a laptop with a windowed interface, defining segments by circumferential position parameters and controlling functions within logical segments, with options for time definitions and sensor values.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual programming is used for PLC and microcontrollers, then control functionality can be achieved, but the complexity and error liability increase significantly making it unreasonable for normal users
Solution Approach 1:
An interactive input device serves as an intermediary between the user and the PLC/microcontroller system. This mediator translates user-friendly parameter inputs into the complex control code required by the rotary machine, shielding users from programming complexity while achieving the desired control functionality.
Solution Approach 2:
The control program is segmented into modular components corresponding to different processing stations and functional areas. Each segment can be independently configured through the interactive input device, allowing users to manage complexity by working with discrete, manageable units rather than a monolithic program.
2Productivity
If programming tools focus on reusing components and libraries, then developer efficiency improves, but usability for normal users deteriorates as they must work at a low programming level
Solution Approach 1:
The system automatically generates and reuses control code segments based on previously configured processing stations and parameters. Rather than requiring users to manually reuse components, the system performs self-service by automatically retrieving and adapting stored configuration data, maintaining both efficiency and usability.
Solution Approach 2:
Control code segments and parameter sets are pre-configured and stored in memory during initial setup or by developers. These preliminary configurations are then automatically retrieved and applied when similar processing requirements are encountered, eliminating the need for users to work at low programming levels while maintaining development efficiency.
3Adaptability or versatility
If different programs are created for different bottle types and coating processes, then customization and adaptability improve, but the time and effort required for program creation increase
Solution Approach 1:
The interactive input device and control system are designed with universal functionality to handle multiple bottle types, coating processes, and processing station configurations through a single unified interface. Parameter sets and processing station definitions are structured to accommodate various applications without requiring separate programming tools, achieving both adaptability and time efficiency.
Solution Approach 2:
Instead of creating entirely different programs for different applications, the system achieves adaptability by changing parameters within a universal program structure. Different bottle types and coating processes are handled by modifying parameters such as rotational speed, processing times, temperature settings, and station configurations, dramatically reducing program creation time while maintaining full versatility.
Data Source
AI summary
The controller and method of the invention generate control instructions for a rotary machine that coats bottles. Gas is supplied to processing stations holding the bottles via a pressure management system. The processing stations are centrally controlled by a programmable PLC or microcontroller with an input device and display terminal. Since rotary machines need to be controlled differently depending on the type of bottles and the type of coating, different programs should be interactively created using the input device and display terminal, which then control the individual components of the rotary machine and the processing stations during the coating process. This eliminates unnecessary errors resulting from preparation of the different programs individually by a normal user.