Universal Mobile Robot Changeover for Plastic Container Heating and Forming
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Solution Overview
Problem
Current methods for changing components in plastic container production, such as shielding plates and blow molds, are time-consuming, complex, and ergonomically disadvantageous, often leading to incorrect assembly and limited system access.
Innovation Solution
A system utilizing a changing device with a mobile robot to interchange elements of both the heating and forming devices, allowing for fully automatic and efficient switching between different container types, including a transport device, holding devices, and interchangeable format parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual changing of heating mandrels and shielding plates is performed, then the system can be changed to different container types, but the changing process is very time-consuming and the system cannot be operated during changing
Solution Approach 1:
The heating device is divided into modular components (heating mandrels, shielding plates, holders) that can be independently changed. The magazine device stores multiple sets of these segmented components, allowing rapid replacement without changing the entire heating device structure.
Solution Approach 2:
Multiple sets of heating mandrels, shielding plates, and holders are pre-loaded into the magazine device before production starts. This preliminary preparation allows the mobile robot to perform simple replacement operations rather than complex assembly during changing.
2Adaptability or versatility
If blow molds are changed manually, then different container types can be produced, but the process is complex and ergonomically disadvantageous due to the heavy weight of blow molds
Solution Approach 1:
The manual mechanical lifting and positioning operation is replaced by a mobile robot system. The robot's gripper device automatically grasps, lifts, and positions the heavy blow molds, eliminating the need for manual handling and associated ergonomic problems.
Solution Approach 2:
The mobile robot acts as an intermediary between the operator and the heavy blow molds. The robot carries the molds from the magazine device to the forming device, mediating the transfer and eliminating direct human contact with heavy components.
3Adaptability or versatility
If manual assembly of blow molds, heating mandrels, or shielding plates is performed, then component replacement is possible, but incorrect or faulty assembly often occurs
Solution Approach 1:
The system performs self-assembly through the mobile robot's automated gripper operations. The robot automatically positions components in the correct orientation and location based on pre-programmed sequences, eliminating human error in assembly procedures.
Solution Approach 2:
The system incorporates sensors to detect the position and status of components during assembly. This feedback mechanism ensures that components are correctly positioned and assembled, providing verification and allowing corrective action if errors are detected.
4Extent of automation
If stationary robot systems are used for automatic change of blow molds, then changing is automated, but access to the system is limited
Solution Approach 1:
The robot system transitions from stationary to mobile. The mobile robot can dynamically move to different positions around the forming device and heating device, providing both automated changing capability and flexible access to various components and areas of the system.
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
Facilitates rapid and accurate changeovers of heating mandrels, shielding plates, and blow molds, enhancing operational efficiency and reducing assembly errors, while enabling continuous system operation.
Implementation Method 1
at least one heating unit (25) that heats the plastic preforms (10) during their transport
Implementation Method 2
suitable for expanding the plastic preforms heated by the heating device by subjecting them to a flowable (and in particular gaseous) medium (in particular compressed air)
Data Source
Figure 1
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Figure 4~5
AI summary
Plant (1) for manufacturing plastic containers (20) with a heating device (2) for heating plastic preforms (10), wherein this heating device comprises a transport device (22) for transporting plastic preforms (10) along a predetermined first transport path (P1), a plurality of holding devices (24) for holding the plastic preforms (10), and at least one heating device which heats the plastic preforms during their transport and with a forming device (4) for forming the plastic preforms into plastic containers, which is suitable for expanding the plastic preforms heated by the heating device (2) by applying a flowable medium, wherein the forming device comprises a plurality of forming stations.which transform the plastic preforms into the plastic containers and wherein both the heating device (2) and the forming device (4) have interchangeable elements, characterized in that the system has an exchange device (6) which is suitable for changing both interchangeable elements of the heating device and interchangeable elements (44) of the forming device.