WO2005092591A2 - Process and system for monitoring and controlling manufacturing of plastic containers - Google Patents
Process and system for monitoring and controlling manufacturing of plastic containers Download PDFInfo
- Publication number
- WO2005092591A2 WO2005092591A2 PCT/US2005/006517 US2005006517W WO2005092591A2 WO 2005092591 A2 WO2005092591 A2 WO 2005092591A2 US 2005006517 W US2005006517 W US 2005006517W WO 2005092591 A2 WO2005092591 A2 WO 2005092591A2
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- containers
- raw materials
- mold
- monitoring
- equipment
- Prior art date
Links
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C49/00—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
- B29C49/42—Component parts, details or accessories; Auxiliary operations
- B29C49/78—Measuring, controlling or regulating
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
- B29B7/00—Mixing; Kneading
- B29B7/002—Methods
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
- B29B7/00—Mixing; Kneading
- B29B7/02—Mixing; Kneading non-continuous, with mechanical mixing or kneading devices, i.e. batch type
- B29B7/22—Component parts, details or accessories; Auxiliary operations
- B29B7/28—Component parts, details or accessories; Auxiliary operations for measuring, controlling or regulating, e.g. viscosity control
- B29B7/283—Component parts, details or accessories; Auxiliary operations for measuring, controlling or regulating, e.g. viscosity control measuring data of the driving system, e.g. torque, speed, power
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
- B29B7/00—Mixing; Kneading
- B29B7/30—Mixing; Kneading continuous, with mechanical mixing or kneading devices
- B29B7/58—Component parts, details or accessories; Auxiliary operations
- B29B7/60—Component parts, details or accessories; Auxiliary operations for feeding, e.g. end guides for the incoming material
- B29B7/603—Component parts, details or accessories; Auxiliary operations for feeding, e.g. end guides for the incoming material in measured doses, e.g. proportioning of several materials
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
- B29B7/00—Mixing; Kneading
- B29B7/30—Mixing; Kneading continuous, with mechanical mixing or kneading devices
- B29B7/58—Component parts, details or accessories; Auxiliary operations
- B29B7/72—Measuring, controlling or regulating
- B29B7/728—Measuring data of the driving system, e.g. torque, speed, power, vibration
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
- B29B7/00—Mixing; Kneading
- B29B7/74—Mixing; Kneading using other mixers or combinations of mixers, e.g. of dissimilar mixers ; Plant
- B29B7/7461—Combinations of dissimilar mixers
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
- B29B7/00—Mixing; Kneading
- B29B7/74—Mixing; Kneading using other mixers or combinations of mixers, e.g. of dissimilar mixers ; Plant
- B29B7/7476—Systems, i.e. flow charts or diagrams; Plants
- B29B7/748—Plants
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
- B29B7/00—Mixing; Kneading
- B29B7/74—Mixing; Kneading using other mixers or combinations of mixers, e.g. of dissimilar mixers ; Plant
- B29B7/7476—Systems, i.e. flow charts or diagrams; Plants
- B29B7/7485—Systems, i.e. flow charts or diagrams; Plants with consecutive mixers, e.g. with premixing some of the components
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/17—Component parts, details or accessories; Auxiliary operations
- B29C45/18—Feeding the material into the injection moulding apparatus, i.e. feeding the non-plastified material into the injection unit
- B29C45/1816—Feeding auxiliary material, e.g. colouring material
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/17—Component parts, details or accessories; Auxiliary operations
- B29C45/76—Measuring, controlling or regulating
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
- B29C48/09—Articles with cross-sections having partially or fully enclosed cavities, e.g. pipes or channels
- B29C48/10—Articles with cross-sections having partially or fully enclosed cavities, e.g. pipes or channels flexible, e.g. blown foils
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/25—Component parts, details or accessories; Auxiliary operations
- B29C48/92—Measuring, controlling or regulating
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C49/00—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
- B29C49/02—Combined blow-moulding and manufacture of the preform or the parison
- B29C2049/023—Combined blow-moulding and manufacture of the preform or the parison using inherent heat of the preform, i.e. 1 step blow moulding
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C49/00—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
- B29C49/42—Component parts, details or accessories; Auxiliary operations
- B29C49/78—Measuring, controlling or regulating
- B29C2049/7874—Preform or article shape, weight, defect or presence
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C49/00—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
- B29C49/42—Component parts, details or accessories; Auxiliary operations
- B29C49/78—Measuring, controlling or regulating
- B29C2049/788—Controller type or interface
- B29C2049/78805—Computer or PLC control
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C2948/00—Indexing scheme relating to extrusion moulding
- B29C2948/92—Measuring, controlling or regulating
- B29C2948/92009—Measured parameter
- B29C2948/92085—Velocity
- B29C2948/92095—Angular velocity
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C2948/00—Indexing scheme relating to extrusion moulding
- B29C2948/92—Measuring, controlling or regulating
- B29C2948/92009—Measured parameter
- B29C2948/92085—Velocity
- B29C2948/92104—Flow or feed rate
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C2948/00—Indexing scheme relating to extrusion moulding
- B29C2948/92—Measuring, controlling or regulating
- B29C2948/92009—Measured parameter
- B29C2948/92209—Temperature
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C2948/00—Indexing scheme relating to extrusion moulding
- B29C2948/92—Measuring, controlling or regulating
- B29C2948/92323—Location or phase of measurement
- B29C2948/92352—Inserts
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C2948/00—Indexing scheme relating to extrusion moulding
- B29C2948/92—Measuring, controlling or regulating
- B29C2948/92323—Location or phase of measurement
- B29C2948/92361—Extrusion unit
- B29C2948/92371—Inlet shaft or slot, e.g. passive hopper; Injector, e.g. injector nozzle on barrel
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C2948/00—Indexing scheme relating to extrusion moulding
- B29C2948/92—Measuring, controlling or regulating
- B29C2948/92323—Location or phase of measurement
- B29C2948/92485—Start-up, shut-down or parameter setting phase; Emergency shut-down; Material change; Test or laboratory equipment or studies
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C2948/00—Indexing scheme relating to extrusion moulding
- B29C2948/92—Measuring, controlling or regulating
- B29C2948/92504—Controlled parameter
- B29C2948/92514—Pressure
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C2948/00—Indexing scheme relating to extrusion moulding
- B29C2948/92—Measuring, controlling or regulating
- B29C2948/92504—Controlled parameter
- B29C2948/9258—Velocity
- B29C2948/9259—Angular velocity
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C2948/00—Indexing scheme relating to extrusion moulding
- B29C2948/92—Measuring, controlling or regulating
- B29C2948/92504—Controlled parameter
- B29C2948/9258—Velocity
- B29C2948/926—Flow or feed rate
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C2948/00—Indexing scheme relating to extrusion moulding
- B29C2948/92—Measuring, controlling or regulating
- B29C2948/92504—Controlled parameter
- B29C2948/92704—Temperature
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C2948/00—Indexing scheme relating to extrusion moulding
- B29C2948/92—Measuring, controlling or regulating
- B29C2948/92819—Location or phase of control
- B29C2948/92847—Inserts
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C2948/00—Indexing scheme relating to extrusion moulding
- B29C2948/92—Measuring, controlling or regulating
- B29C2948/92819—Location or phase of control
- B29C2948/92857—Extrusion unit
- B29C2948/92866—Inlet shaft or slot, e.g. passive hopper; Injector, e.g. injector nozzle on barrel
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C2949/00—Indexing scheme relating to blow-moulding
- B29C2949/07—Preforms or parisons characterised by their configuration
- B29C2949/0715—Preforms or parisons characterised by their configuration the preform having one end closed
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C2949/00—Indexing scheme relating to blow-moulding
- B29C2949/30—Preforms or parisons made of several components
- B29C2949/3064—Preforms or parisons made of several components having at least one components being applied using techniques not covered by B29C2949/3032 - B29C2949/3062
- B29C2949/3074—Preforms or parisons made of several components having at least one components being applied using techniques not covered by B29C2949/3032 - B29C2949/3062 said at least one component obtained by coating
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/022—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the choice of material
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/25—Component parts, details or accessories; Auxiliary operations
- B29C48/285—Feeding the extrusion material to the extruder
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C49/00—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
- B29C49/02—Combined blow-moulding and manufacture of the preform or the parison
- B29C49/06—Injection blow-moulding
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C49/00—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
- B29C49/42—Component parts, details or accessories; Auxiliary operations
- B29C49/42378—Handling malfunction
- B29C49/4238—Ejecting defective preforms or products
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C49/00—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
- B29C49/42—Component parts, details or accessories; Auxiliary operations
- B29C49/64—Heating or cooling preforms, parisons or blown articles
- B29C49/6409—Thermal conditioning of preforms
- B29C49/6427—Cooling of preforms
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
- B29K2105/25—Solid
- B29K2105/253—Preform
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
- B29K2105/26—Scrap or recycled material
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/712—Containers; Packaging elements or accessories, Packages
- B29L2031/7158—Bottles
Definitions
- This invention relates generally to forming plastics, and more particularly to a system and method for monitoring and controlling a plastic forming process.
- the plastic articles can generally be formed at a single site with plastic resin pellets brought to a molding machine and a finished product being removed from the molding machine.
- a supply of plastic pellets is maintained in a silo, is blended with other materials, such as color and additives, and is delivered to a material hopper of an extruder wherein the blended materials are melted and mixed so that they are ready for injection into a mold.
- the melted material is injected into a mold and is cured slightly to form a parison.
- the parison is then transferred to a blow mold wherein pressurized air is used to mold the parison within the mold cavity.
- the bottles can be flame treated, inspected for leaks or imperfections in the threads or panels, and then packaged with other containers for shipment.
- the various portions of the machine for example, the extruder, the parison mold, and the blow mold are controlled by a suitable electronic
- a certificate of compliance can be generated for the particular lot or production run of bottles.
- Changes to the operational parameters of the machine are done by the machine operator in response to information provided by the controller indicting that the machine is operating outside of predetermined limits, or in response to information obtained from sample bottle inspection indicating that the inspected bottle parameters are outside of predetermined quality limits.
- a method of manufacturing and certifying operation of a system for producing plastic containers using equipment having at least one controllable parameter that affects quality of containers produced by the equipment includes inspecting raw materials for parameters that affect manufacturability and acceptability of containers produced from such materials, monitoring operation of the equipment including the at least one controllable parameter, inspecting containers produced by the equipment for variations that affect acceptability of the containers, automatically controlling operation of the equipment to eliminate variations in response to information obtained during the inspecting and monitoring steps, and certifying acceptability of containers produced by the equipment.
- some or all of these steps can be carried out automatically, such as by a controller that monitors the various steps and operational parameters of the manufacturing process to ensure compliance
- the controller desirably is automatically corrected by the controller to achieve operation within the predetermined limits.
- a product manufactured outside predetermined limits or parameters may be automatically diverted away from the production line to scrap.
- the information obtained during the inspection and monitoring steps can be used to generate certificates of compliance and other paperwork documenting the manufacturing process, controls and inspection results. Desirably, the paperwork and certificates can be generated and distributed automatically with minimal or no operator intervention required.
- FIG. 1 is a schematic diagram of a system for manufacturing plastic articles such as plastic containers.
- FIG. 2 is a diagrammatic view of a controller and machine interface
- FIGS 1 and 2 illustrate a system
- the system 10 may also include various inspection devices 20 for inspecting molded containers prior to packaging and shipping the containers.
- raw material such as plastic in the form of pellets is brought into the factory and loaded into a silo 22 or other storage container. When needed, the raw material is removed from the silo 22 and transported to a blending system 24 through an associated hopper 21. In the blending system 24, the raw material is mixed with other materials, such as colorant 23 additives 25, and recycled or regrind material 27, usually in dry form.
- the various materials are preferably provided to the blender through funnels or hoppers 29, 31 and are agitated or otherwise mixed providing a more uniform dry mixture.
- the raw materials are transferred to a material hopper 26 of the extruder 14 wherein the material is gravity fed into the extruder screw chamber 28.
- the raw materials are melted, mixed together and then accumulated in the extruder. From the extruder 14, at
- the melted materials are injected into a cavity of a
- the plastic article is called a preform or parison. After the parison is cured slightly, it is lifted out of the mold 16 and transferred to a cavity of a blow mold 18 wherein pressurized' air is introduced
- inspection stations may include, for example, flame treatment, leak detection, as well as various visual, meckianical electrical or other inspections for various features, characteristics, or imperfections in the threads, the panels or sidewalls of the containers, and the like. Thereafter the containers are typically counted and packaged so they are ready for shipment.
- incoming raw material can be inspected for various parameters affecting quality and the ability to form a finished product.
- the incoming raw materials maybe inspected for such things as presence of contaminants, presence of metal and various mechanical properties such as the melt flow, melt swell index and density of the pellets.
- other inspections and/or tests maybe conducted on the incoming raw material to ensure its integrity and quality as desired.
- Information regarding the raw material may also be provided by the supplier of the material. This information can be entered into a controller or database manually, or automatically such as through use of bar codes or other tags, or by electronic or other data transfer.
- virgin raw materials such as by
- polyethylene or polycarbouate may be combined with colorants, other additives and other materials, including process
- the blending system 24 may include a so-called weight cell blender 32 that mixes or combines the various raw materials according to a prescribed formula or recipe for the product being made to provide each raw material as a percentage of the total composition measured by weight of the materials. Accordingly, the machinery that adds the various raw materials into the blender 24 can be monitored to ensure that the appropriate amount or weight of materials are added to the blender, samples may be taken from the blender to confirm the above, and the output from the blender of the combined raw materials can be monitored and/or sampled and inspected to ensure the appropriate blend of materials is achieved.
- Blending materials can also be conducted at or downstream of the blender. From the blender 24, the combined materials are transferred to the material hopper 26 of the extruder 14 where the materials are fed into the extruder screw chamber 28 where they are melted, mixed together and accumulated in the extruder for subsequent injection.
- Various operational parameters in the material hopper 26 and in the extruder 14 generally can be tracked, monitored and controlled to ensure operation within predetermined
- the flow rate of material into the hopper and from the hopper to the extruder screw chamber can be momtored, as can the
- temperature within the extruder can be monitored and controlled to ensure desired
- the melted and mixed plastic material is injected into a mold cavity 16 usually over a core rod, and is cured slightly to form a
- the pressure at which the melted material is injected in the mold cavity, the temperature of the material in the extruder 14 as it i s injected, the time for the injection, molding and curing portions of the cycle, as "well as the temperature of the mold 16, and number of cycles or parts formed by tfcie mold 16 either in its life or from its last maintenance or repair, can be controlled or monitored.
- Each of these parameters or steps is preferably controlled according to a predetermined procedure or recipe for the particular plastic article being formed.
- Each parameter may have an acceptable range of values or associated tolerance that will produce an acceptable plastic article or may have upper or lower limits or both that must be respected to ensure the quality of the plastic articles being formed.
- Various parameters can be monitored and controlled to ensure compliance with the predetermined procedure in this step of the manufacturing process. Some of these parameters include the time required to transfer the parison from the inj ection mold 16 to the blow mold
- the formed plastic containers After being blow molded and permitted to cool for a desired period of time, the formed plastic containers are removed from the blow mold 18 and indexed to an outfeed station to be removed from molding machine, such as on a conveyor 30.
- the formed plastic articles On the conveyor 30, the formed plastic articles may be moved through a plurality of downstream work and inspection stations 20 to finish the containers 12, inspect the containers 12, ensure compliance with various criteria and to ensure that there are no unacceptable variations and/or anomalies in the containers 12.
- the containers 12 can be flame treated at one station 20a, checked for leaks at a station 20b, inspected visually, electronically, mechanically, or otherwise for contaminants or inclusions in the threads or panels of the containers 12 at other stations 20c, 20d and have various portions measured at other stations 20e, 20f.
- those containers 12 that have passed the inspection process are packaged and made ready for shipment.
- This information may also be used to effect an
- controllable actions such as operational parameters (e.g., cycle times, temperatures, pressures, etc.) or procedures to reduce or eliminate rejected containers.
- the information obtained from the process monitoring is desirably also recorded for historical retrieval, as well to facilitate production of certificates of compliance and other process documentation.
- various sensors and devices are communicated with a process controller or controllers that both record the information obtained from the sensors and ensure that the sensed parameters fall within the prescribed limits for the particular plastic articles being made.
- the controllers are capable of automatically changing at least one controllable action in a process parameter or step that affects quality of containers produced by the machines. Should the corresponding process parameter fall outside predescribed limits, the controllable action can be altered by the electronic controller or processor to, for example, automatically bring the subject process parameter back within the prescribed limits without operator intervention.
- a plurality of process parameters can be automatically monitored and adjusted by the processor or controller to maintain the process parameters within the prescribed limits throughout a production run. Included in these process parameters that can be controlled automatically are at least the operation parameters of blending
- the extruder e.g. flow rate, temperature, pressure, screw torque, screw rotational speed
- the injection mold e.g. a mixture of materials
- the extruder e.g. flow rate, temperature, pressure, screw torque, screw rotational speed
- the injection mold e.g. a mixture of materials
- the extruder e.g. flow rate, temperature, pressure, screw torque, screw rotational speed
- the injection mold e.g. ratio or mixture of materials
- the extruder e.g. flow rate, temperature, pressure, screw torque, screw rotational speed
- blow mold e.g. air pressure, air
- FIG.2 diagrammatically illustrates a controller 34 communicating
- the controller may include several controllers.
- the controllers m y be associated with different functions or machines and are preferably
- the controller may include a machine logic controller and a heat or temperature controller.
- the machine logic controller can interface with the various machines and sensors to set certain operational parameters (e.g. cycle times, pressures, etc.) and ensure the appropriate parameters are met in operation.
- the heat controller ensures the machines and systems operate at the proper temperature throughout the manufacturing process and can indicate a fault in the heating system to othei- controllers or systems.
- plastic articles produced when a process parameter is outside of its prescribed limits are preferably automatically quarantined as they may contain unacceptable variations or anomalies. The quarantined bottles can be subsequently inspected to determine if they comply with predetermined parameters or if they have unacceptable variations and must be rejected or scrapped.
- the machine monitoring is integrated so that all information, obtained for a particular lot of material or production run of bottles can be readily- obtained and used, for example, to generate a certificate of compliance for the corresponding bottles produced.
- the machine line is preferably automatically configured in response to a tooling change, such as when one or more of the molds used to form the plastic articles are changed.
- the molds may
- the controller can determine when it is installed. Based on the mold that is installed, the controller can
- the controller can configure and operate the various machines to provide the desired material composition, and to process and mold the material with the desired temperatures, pressures, cycle times and inspection criteria.
- the identifier on the tool such as a
- mold is an RF or radio frequency tag that is automatically sensed by or communicated to the controller or other receiver or relay device upon installation. From the tag information the controller can configure the machine line and process parameters in accordance with a predetermined recipe or process map associated with the tool.
- identifiers other then RF tags may be used so that the system can automatically identify the tool being installed, or an operator may input a code associated with the tool from which the controller can determine the tool being installed and the product to be made.
- the controller may communicate with a database 36 (FIG. 2) or other source of information that contains the process parameters and predetermined
- a wide range of process parameters and steps can be automatically set based on the particular tool installed in the system.
- the operating pressures, temperatures and cycle times can be communicated from a database 36 to the controller 34 and from the controller 34
- the database is Smart Stream by D & B.
- the blender ratios can be set for the proper material mixture, the extruder parameters can be set and the molding and post molding operations and inspections can be set in accordance with the desired product to be made. Any items that need to be manually set can be communicated to the operator, such as by display of appropriate information on a monitor, hard copy printout, or generated and stored file information for the operator's review.
- the identifying tag on the tools can also be useful in tracking the number of cycles for which the tool has been used, number of products produced by the
- the number of cycles on the tool can be recorded and stored in a database.
- the database or controller can provide an indication when maintenance needs to be completed on the tool for various maintenance procedures required based on the completed number of cycles in each tool.
- the operator or other person or controller can automatically be notified when maintenance is required on individual tools.
- lifetime maintenance records can be kept by tool in the server, or otherwise displayed or communicated to other controllers or individuals.
- the information from the sample container inspection can be included with the information obtained from the process monitoring, can be stored in the historical database or files, and can be used for compliance paperwork. Should one or more sample containers fail inspection, the information relating to the failure can be used to change a process parameter (either via the operator or automatically such as by the controller), or to change the predetermined limits or tolerances for the process parameters if the defective container was manufactured within the previously set limits or tolerances for the corresponding process parameter.
- the efficiency of the production line can be tracked by tracking the production rate of acceptable product as well as the down time of the production line.
- Tracking of total production, down time of the machine, reasons for the downtime, offware and reasons for offware can be tracked and reported to a central database or to the controller.
- the downtime can be tracked by cause.
- the cause of the downtime can be automatically
- sampling and machine line configuration phases can be incorporated in a database or in the controller to provide information for various lots or production runs of containers demonstrating the various operational parameters under which the
- This information can be used to print various reports, to complete compliance paperwork either automatically or manually, and to produce certificates of compliance for the containers.
- the operational parameters and other compliance paperwork data being stored electronically either in the processor, controller or database, the compliance paperwork and certificates of compliance can be transmitted electronically to substantially anywhere in the world, and can be provided in hard copy form and included with boxes, of containers prior to shipment. Automatically generating the compliance paperwork and certificates of compliance can eliminate or reduce human error,
- Existing machines can be retrofitted with an appropriate interface allowing them to be networked together and with the controller for appropriate communication and monitoring between them.
- Newer machines are preferably provided with more advanced processing and networking capabilities including advanced PC based HMI systems or other advanced controls and networking interfaces to facilitate implementation of the production line integration, monitoring and configuration system for producing plastic articles.
- Personnel associated with the manufacturing process such as material handlers, equipment operators and inspectors can be tracked and recorded.
- ID cards or tags commonly used
- ID cards or tags could be automatically sensed by an appropriate sensor communicated with, for example,
- the ID cards could also be scanned or swiped through a card reader operable to identify and record the identity of people associated with the manufacturing process.
- the ID cards could also be used for security, safety or other control reason and can be necessary to start, unlock or control various features or machines.
- different people may be given different access to machines or information and the approved access of a person can be verified or determined by their ID card, or other arrangement or identifier such as by logging onto a network, entering a password, or the like.
- the employee identification scheme can also be used to track the actions taken by each employee for quality control or other reasons.
- the employee who wants to alter the setting must identify himself (such as with an ID card, code, password, etc.) to provide the access to do so and to identify that employee as the person who altered the setting.
- the entire process, from initial inspection of raw materials to final packaging of finished containers can be accomplished in an integrated production line and momtored so that compliance with all process parameters can
- Plastic articles formed according to the process parameters can be ensured.
- Plastic articles formed according to the process parameters can be ensured.
- the certificates of compliance can be automatically generated or generated with minimal operator input, and the action
- the goal is to reduce and even eliminate anomalies or unacceptable variations in the bottles to provide customers with high quality bottles free from unacceptable variations. While it may not be feasible in some production lines to inspect every bottle, statistical analysis of the production runs of bottles can be improved by automatic product sampling at prescribed intervals and by the more detailed process monitoring of the integrated production line as set forth herein.
- the machines used in producing the plastic containers have been described as communicating with a controller, although each machine may have its own controller and the controllers may in rum be communicated with a master or central controller or processor.
- the particular embodiment set forth is directed to the production of plastic containers, other articles can be manufactured by the system and method described. Of course, other modifications or substitutions can be made and will be readily apparent to
Abstract
Description
Claims
Priority Applications (6)
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BRPI0508431-8A BRPI0508431A (en) | 2004-03-03 | 2005-03-02 | plastic modeling process monitoring and control |
JP2007501888A JP4676483B2 (en) | 2004-03-03 | 2005-03-02 | Method and system for monitoring and controlling plastic forming process |
MXPA06009852A MXPA06009852A (en) | 2004-03-03 | 2005-03-02 | Process and system for monitoring and controlling manufacturing of plastic containers. |
CA002557338A CA2557338A1 (en) | 2004-03-03 | 2005-03-02 | Plastic forming process monitoring and control |
EP05724125A EP1727659A2 (en) | 2004-03-03 | 2005-03-02 | Process and system for monitoring and controlling manufacturing of plastic containers |
NO20064475A NO20064475L (en) | 2004-03-03 | 2006-10-03 | Plastic forming process monitoring and control |
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US10/793,522 US7534378B2 (en) | 2004-03-03 | 2004-03-03 | Plastic forming process monitoring and control |
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- 2005-03-02 MX MXPA06009852A patent/MXPA06009852A/en active IP Right Grant
- 2005-03-02 BR BRPI0508431-8A patent/BRPI0508431A/en not_active IP Right Cessation
- 2005-03-02 CA CA002557338A patent/CA2557338A1/en not_active Abandoned
- 2005-03-02 CN CNB2005800138720A patent/CN100548622C/en not_active Expired - Fee Related
- 2005-03-02 EP EP05724125A patent/EP1727659A2/en not_active Withdrawn
- 2005-03-02 JP JP2007501888A patent/JP4676483B2/en not_active Expired - Fee Related
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2006
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Cited By (3)
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US9545748B2 (en) | 2008-03-06 | 2017-01-17 | Khs Corpoplast Gmbh | Method and device for blow-molding containers |
EP2447033A1 (en) * | 2010-10-26 | 2012-05-02 | Krones AG | Method for manufacturing plastic containers and/or plastic pre-forms |
US8795575B2 (en) | 2010-10-26 | 2014-08-05 | Krones Ag | Method for producing plastic containers and/or plastic preforms |
Also Published As
Publication number | Publication date |
---|---|
WO2005092591A3 (en) | 2005-11-10 |
US7534378B2 (en) | 2009-05-19 |
NO20064475L (en) | 2006-11-17 |
MXPA06009852A (en) | 2007-04-16 |
BRPI0508431A (en) | 2007-07-31 |
JP2007526156A (en) | 2007-09-13 |
JP4676483B2 (en) | 2011-04-27 |
CN1964832A (en) | 2007-05-16 |
US20050194705A1 (en) | 2005-09-08 |
CA2557338A1 (en) | 2006-10-06 |
EP1727659A2 (en) | 2006-12-06 |
CN100548622C (en) | 2009-10-14 |
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