Variable Cycle Blow Molding for Line Speed Adaptability
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Solution Overview
Problem
Existing blow-molding machines operate at a constant output rate, leading to complications and increased costs when trying to adjust production line speeds, resulting in potential malformation or dimensional issues in containers, which can cause line stoppages and affect production quality and quantity.
Innovation Solution
Implementing a method where the blow-molding cycle includes two rates, with the second cycle having a lower rate and a delayed degassing phase to create a buffer time, maintaining consistent essential step durations and preventing quality degradation, while allowing continuous operation of packaging steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the blow-molding machine operates at a constant output rate, then the production process is simple and stable, but the production line cannot adapt to downstream machine breakdowns or speed variations, requiring costly buffer zones
Solution Approach 1:
The patent applies dynamics by making the blow-molding cycle duration variable rather than constant. The control system dynamically adjusts the cycle time based on downstream machine status, allowing the production line to adapt to speed variations and breakdowns without requiring buffer zones. This transforms a static constant-rate system into a dynamic adaptive system.
Solution Approach 2:
The patent changes the parameter of cycle duration from fixed to variable. By modifying the cycle time parameter in response to downstream machine conditions, the system achieves adaptability without adding complex hardware buffers. The control device adjusts operational parameters (cycle speed, timing) to match downstream capabilities.
2Productivity
If the blow-molding machine varies its output rate to match downstream machine needs, then production flexibility improves, but container quality may deteriorate due to malformations or dimensional variations
Solution Approach 1:
The patent applies preliminary action by pre-planning and pre-coordinating cycle duration adjustments with downstream machine status. The control device anticipates downstream needs and adjusts blow-molding cycles in advance, ensuring quality parameters are maintained while achieving production flexibility. This prevents reactive adjustments that could compromise container quality.
Solution Approach 2:
The patent implements feedback mechanisms where the control device continuously monitors downstream machine status and adjusts blow-molding cycle parameters accordingly. This closed-loop control ensures that production rate variations do not compromise container quality, as adjustments are based on real-time feedback from the production line status.
3Reliability
If the production line speed is reduced to accommodate downstream issues, then continuous operation is maintained, but production efficiency decreases
Solution Approach 1:
The patent applies periodic action by implementing variable cycle durations rather than continuous constant-rate operation. The system periodically adjusts cycle times based on downstream machine status, maintaining continuous operation when possible while accepting temporary slowdowns only when necessary. This prevents prolonged efficiency loss by returning to optimal speed as soon as downstream conditions permit.
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
This approach ensures continuous production line operation by maintaining the quality of formed containers despite variations in production rates, preventing malformations and dimensional issues, and allowing for flexible adjustment of production line speeds without affecting container quality.
Implementation Method 1
the pressurized blow-molding fluid, typically air, is injected into the blanks so as to transform them into containers
Implementation Method 2
the formed containers are degassed internally... comprises a degassing of the pressurized blow-molding fluid (typically air) through its venting
Data Source
AI summary
Disclosed is a method for forming blanks made from plastic material into containers, the method including steps of blowing into the blanks in such a way as to form them into containers, then internally degassing the formed containers. In the method, the steps are carried out according to a first cycle at a first rate. Then, during a second subsequent cycle of steps carried out at a second rate slower than the first rate, a time delay is added with respect to the first cycle, during or after degassing, such that the second cycle lasts longer than the first.