Shaping Machine Target Profiles for Cross-Configuration Process Control
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Solution Overview
Problem
Establishing a target value progression for shaping machines, such as plastic injection moulding machines, is complex due to the complexity of physical relationships between process parameters, making it difficult for users to achieve desired actual value progressions, especially when switching between different machines or moulding tools with varying structures.
Innovation Solution
A method and computer program product that allow for the establishment of a target value progression for process parameters in shaping machines, enabling the achievement of desired actual value progressions by determining a reference value progression from one configuration and adapting it for another, ensuring the actual value progression meets desired properties within a predetermined tolerance range, even when using different machines or moulding tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a target value progression is established for a process parameter to achieve a desired actual value progression, then the manufacturing precision is improved, but the device complexity increases due to the complexity of physical relationships
Solution Approach 1:
The patent creates a digital model (copy) of the physical shaping machine that includes the complex physical relationships. This virtual model allows users to simulate and determine target value progressions without directly dealing with the complexity of the actual physical system. The digital twin captures the relationships between process parameters and actual values, enabling precise control while shielding the user from complexity.
2Manufacturing precision
If a suitable target value progression is established through manual adjustment, then the manufacturing precision is improved, but the loss of time increases due to the time-consuming and laborious nature of the process
Solution Approach 1:
The patent performs preliminary calculations and simulations to determine the optimal target value progression before actual production begins. The digital model pre-computes the relationship between process parameters and actual values, storing this information for rapid retrieval and application. This eliminates the need for time-consuming manual adjustment during setup or when changing production parameters.
3Manufacturing precision
If the procedure is repeated for each new shaping machine or moulding tool configuration, then the manufacturing precision is maintained, but the loss of time increases due to the need to repeat the procedure
Solution Approach 1:
The patent creates a universal digital model framework that can represent different shaping machine configurations and moulding tools. The system stores multiple digital twins for different machines and tools, and can automatically select and adapt the appropriate model when a configuration changes. This universal approach allows the same methodology to be applied across different equipment without repeating the entire procedure, significantly reducing setup time while maintaining precision.
4Adaptability or versatility
If the shaping machine structure varies between machines or tools, then the adaptability increases, but the device complexity increases making it unclear how to establish target value progression
Solution Approach 1:
The patent creates a digital copy (digital twin) of each specific machine configuration that captures its unique physical relationships and characteristics. When a user needs to work with a different machine or tool, they simply load the corresponding digital model, which already encodes the specific physical relationships for that equipment. This allows the system to adapt to different structures without exposing the user to the underlying complexity.
Data Source
AI summary
A target value progression for a process parameter functioning as a setting variable is established so that an actual value progression for a selected variable has a desired property, or the desired actual value progression itself ensues. The actual value progression occurring in relation to the first configuration is predetermined as a reference value progression for the selected variable, and a target value progression for the process parameter functioning as the setting variable is established by a computer so that the reference value progression as the actual value progression with the desired property or the desired actual value progression itself ensues when the shaping machine in the second configuration operates in a production cycle in accordance with the selected target value progression for the at least one process parameter functioning as the setting variable.