Thermoplastic Container Blow-Molding Calibration for Wall Thickness
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Solution Overview
Problem
Existing manufacturing processes for thermoplastic containers are time-consuming and require significant manual adjustment of parameters to achieve compliance, leading to increased costs and production downtime due to non-conformities in container thickness, which existing solutions fail to address efficiently.
Innovation Solution
A method involving a calibration process that measures and adjusts control parameters such as heating temperature, blowing pressure, and pre-blowing flow rate to optimize thermal conditioning and forming, using a control unit to record and modify parameters based on real-time thickness measurements to achieve desired container thickness specifications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual adjustment of heating and forming parameters is performed to achieve container thickness compliance, then manufacturing precision is improved, but loss of time increases due to tedious parameter adjustment and production downtime
Solution Approach 1:
The patent applies preliminary action by performing a calibration phase before production where the system pre-determines the relationship between heating parameters and container thickness. During this calibration, the system measures thickness at various heating powers and stores this data. During actual production, the system can immediately retrieve and apply the appropriate parameters based on desired thickness specifications, eliminating the need for time-consuming manual adjustments.
Solution Approach 2:
The system implements self-service by automatically determining optimal heating parameters based on pre-stored calibration data. The control unit automatically selects heating power levels and duration based on the desired container thickness, without requiring operator intervention. This automation allows the system to self-adjust parameters in real-time based on production requirements.
2Manufacturing precision
If multiple parameters are adjusted during thermal conditioning and forming phases to correct thickness drift, then manufacturing precision is improved, but device complexity increases due to numerous parameters requiring coordination
Solution Approach 1:
The patent applies segmentation by separating the control of heating parameters from forming parameters. The system divides the parameter adjustment into distinct segments: heating power levels, heating duration, and forming parameters. Each segment is independently calibrated and stored in the control unit, allowing operators to adjust only the specific segment that needs correction without managing all parameters simultaneously, thus reducing complexity.
Solution Approach 2:
The calibration phase performs preliminary action by pre-determining and storing the optimal combinations of heating and forming parameters for different thickness requirements. This pre-computed parameter set eliminates the need for complex real-time coordination during production, as the system simply retrieves and applies the pre-determined parameter combination corresponding to the desired thickness.
3Manufacturing precision
If extensive preliminary tests are conducted to achieve compliant container production, then manufacturing precision is improved, but productivity decreases due to significant time impact on production volume
Solution Approach 1:
The patent resolves this contradiction by performing all necessary preliminary tests and parameter optimization during an initial calibration phase before production begins. Once calibrated, the system can rapidly produce compliant containers without repeating the extensive testing process. This separates the time-consuming precision work from the high-speed production phase, allowing both high precision and high productivity during actual production.
Solution Approach 2:
The system applies copying by creating a digital model or lookup table of optimal parameters during calibration that can be repeatedly copied and applied during production. Instead of performing physical tests for each production batch, the system copies the proven parameter settings from calibration to production, maintaining quality consistency while dramatically reducing the time required for each production run.
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
Enables rapid optimization of manufacturing processes to maintain consistent container thickness without downtime, reducing production costs and improving efficiency by automatically adjusting parameters to meet quality standards.
Implementation Method 1
a first phase called heating of the hollow bodies, during which a succession of hollow bodies is heated in the heating unit to a reference temperature at which the hollow bodies are in a malleable state
Implementation Method 2
a pressurized fluid is injected into each hollow body by the injection device also called the corresponding nozzle to give the preform the final shape of the container
Implementation Method 3
a stretching phase carried out by means of a movable stretching rod arranged to apply a stretching force to the bottom of a hollow body in a mold to stretch the preform along its axis
Data Source
Figure 1
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AI summary
The present invention relates to a method for manufacturing thermoplastic containers by blow molding or stretch blow molding of a hollow body previously heated in an oven and then placed in a mold, the steps of heating the hollow bodies, pre-blowing and blowing being controlled by a control unit from different so-called control parameters; said method is remarkable in that it comprises a preliminary step called calibration which comprises at least the following steps of: producing containers from first control parameters; measuring the thickness of the wall of said containers at the outlet of the mold, at at least two different heights; recording said reference thickness in a memory unit; modifying at least one control parameter;measuring the wall thickness of said containers at the outlet of the mold, at at least two different heights, after the modification of each control parameter; recording the thicknesses; comparing said measured thicknesses recorded with the theoretical thicknesses that should have been obtained after modifications of said parameter(s) by following the pre-determined correction coefficients; and finally modifying the predetermined correction coefficients so that the thicknesses measured after modification of the control parameter(s) correspond to the theoretical thicknesses that should have been obtained with the previous pre-determined coefficients.;