SYSTEM AND METHOD FOR SYNCHRONIZATION OF A CONTAINER FORMING MACHINE AND A CONTAINER PROCESSING MACHINE IN A CONTAINER PROCESSING PLANT

• US 20180346307A1
• Filed: 06/01/2018
• Published: 12/06/2018
• Est. Priority Date: 06/02/2017
• Status: Active Grant

• Current Assignee: Sidel Participations (Tetra Laval Holdings BV)
• Original Assignee: Sidel Participations (Tetra Laval Holdings BV)
• Inventors: SORBI, Federica
• Granted Patent: US 10,450,179 B2
• Time in Patent Office: Days
• CPC Class Codes: B29C 2049/023 using inherent heat of the preform, i.e. 1 step blow moulding
• CPC Class Codes: B29C 2049/4863 Mould identification, e.g. chip on mould with ID and process data
• CPC Class Codes: B29C 2049/78805 Computer or PLC control
• CPC Class Codes: B29C 2049/7882 Control interface, e.g. display
• CPC Class Codes: B29C 2949/0715 the preform having one end closed
• CPC Class Codes: B29C 49/006 Blow-moulding plants, e.g. using several blow-moulding apparatuses cooperating
• CPC Class Codes: B29C 49/06 Injection blow-moulding
• CPC Class Codes: B29C 49/062 following an arcuate path, e.g. rotary or oscillating-type
• CPC Class Codes: B29C 49/4205 Handling means, e.g. transfer, loading or discharging means handling of inserts or reinforcements B29C49/20; handling of linings or labels B29C49/2408
• CPC Class Codes: B29C 49/42069 Means explicitly adapted for transporting blown article
• CPC Class Codes: B29C 49/42095 Rotating wheels or stars
• CPC Class Codes: B29C 49/4236 Drive means
• CPC Class Codes: B29C 49/42362 Electric drive means, e.g. servomotors
• CPC Class Codes: B29C 49/42378 Handling malfunction
• CPC Class Codes: B29C 49/4238 Ejecting defective preforms or products
• CPC Class Codes: B29C 49/42407 Procedures for start-up or material change
• CPC Class Codes: B29C 49/4273 Auxiliary operations after the blow-moulding operation not otherwise provided for
• CPC Class Codes: B29C 49/42802 a closure or a sealing foil to the article or pincing the opening
• CPC Class Codes: B29C 49/42808 Filling the article
• CPC Class Codes: B29C 49/78 Measuring, controlling or regulating
• CPC Class Codes: B65G 29/00 : Rotary conveyors, e.g. rotating discs, arms, star-wheels or cones mechanical projectors B65G31/00; screw or rotary spiral conveyors B65G33/00
• CPC Class Codes: B65G 47/846 : Star-shaped wheels or wheels equipped with article-engaging elements
• CPC Class Codes: B67C 2003/227 : Additional apparatus related to blow-moulding of the containers, e.g. a complete production line forming filled containers from preforms
• CPC Class Codes: B67C 3/007 : Applications of control, warning or safety devices in filling machinery flow-control B67C3/28
• CPC Class Codes: B67C 7/0013 : Synchronising
• CPC Class Codes: G05B 19/4062 : Monitoring servoloop, e.g. overload of servomotor, loss of feedback or reference
• CPC Class Codes: G05B 2219/50193 : Safety in general

Abstract

A synchronization system for a container-processing plant, including a container-forming machine configured to form a container, the container-forming machine having a first rotating wheel for rotating the container about a first rotation axis; a container-filling machine operatively coupled to the container-forming machine and configured to fill the container, the container-filling machine having a second rotating wheel for rotating the container about a second rotation axis; and at least one electric motor configured to cause the first rotating wheel and the second rotating wheel to rotate, the synchronization system comprising: a position sensor provided in the container-forming machine and configured to detect a rotating position of the first rotating wheel and to generate a position detection signal; at least one control unit configured to: receive information associated with the position detection signal; synchronize the rotation of the second rotating wheel to the rotation of the first rotating wheel based on the information associated with the position detection signal; and synchronize the rotation of the container-forming machine and container-filling machine from a zero speed up to a full operating speed of the container forming machine at which processing operations are designed to be performed.

Claims

1. A synchronization system for a container-processing plant, including a container-forming machine configured to form a container, the container-forming machine having a first rotating wheel for rotating the container about a first rotation axis;

a container-filling machine operatively coupled to the container-forming machine and configured to fill the container, the container-filling machine having a second rotating wheel for rotating the container about a second rotation axis; and

at least one electric motor configured to cause the first rotating wheel and the second rotating wheel to rotate, the synchronization system comprising;

a position sensor provided in the container-forming machine, and configured to detect a rotating position of the first rotating wheel and to generate a position detection signal;

at least one control unit configured to;

receive information associated with the position detection signal;

synchronize the rotation of the second rotating wheel to the rotation of the first rotating wheel based on the information associated with the position detection signal; and

synchronize the rotation of the container-forming machine and container-filling machine from a zero speed up to a full operating speed of the container forming machine at which processing operations are designed to be performed.

2. The system according to claim 1, wherein the position sensor is an absolute encoder, and the at least one electric motor is a brushless motor.

3. The system according to claim 1, wherein the at least one control unit is configured to synchronize the rotation of the container-filling machine with respect to the container-forming machine at the zero speed of the container-forming machine, so as to allow the container-forming machine and the container-filling machine to run synchronized during a testing procedure.

4. The system according to claim 1, wherein the at least one control unit is configured to synchronize the rotation of the container-filling machine with respect to the container-forming machine at the zero speed of the container-forming machine, during restart of the processing operations after a fault has been detected at the container-forming machine.

5. The system according to claim 1, wherein the at least one control unit is configured to synchronize the rotation of the container-filling machine with respect to the container-forming machine at the full operating speed, during restart of the processing operations after a fault has been detected at the container-filling machine.

6. The system according to claim 1, wherein the information associated with the position detection signal includes a position and a speed of rotation of the first rotating wheel around the first rotation axis.

7. The system according to claim 1, wherein the container-filling machine further includes a number of transfer star wheels designed to transfer containers and operatively coupled to the second rotating wheel, and wherein the at least one control unit is configured to generate a virtual rotation axis based on the information associated with the position detection signal, and to control rotation of the second rotating wheel and the transfer star wheels according to the generated virtual rotation axis.

8. The system according to claim 1, wherein the at least one control unit includes a first control unit associated with the container-forming machine and a second control unit associated with the container-filling machine, and the system further comprising a digital coupling bus, coupling the first and second control units and carrying the information associated to the position detection signal.

19. The plant according to claim 1, wherein the at least one control unit is configured to synchronize the rotation of the container-filling machine with respect to the container-forming machine at the zero speed of the container-forming machine, so as to allow the container-forming machine and the container-filling machine to run synchronized during a testing procedure.

20. The plant according to claim 1, wherein the at least one control unit is configured to synchronize the rotation of the container-filling machine with respect to the container-forming machine at the zero speed of the container-forming machine, during restart of the processing operations after a fault has been detected at the container-forming machine.

21. The plant according to claim 1, wherein the at least one control unit is configured to synchronize the rotation of the container-filling machine with respect to the container-forming machine at the full operating speed, during restart of the processing operations after a fault has been detected at the container-filling machine.

9. (canceled)

10. A synchronization method for a container-processing plant, including a container-forming machine configured to form a container, the container-forming machine having a first rotating wheel for rotating the container about a first rotation axis;

a container-filling machine operatively coupled to the container-forming machine and configured to fill the container, the container-filling machine having a second rotating wheel for rotating the container about a second rotation axis;

at least one electric motor configured to cause the first rotating wheel and the second rotating wheel to rotate; and

a position sensor provided in the container-forming machine and configured to detect a rotating position of the first rotating wheel and to generate a position detection signal;

the method comprising;

synchronizing, by at least one control unit, the rotation of the second rotating wheel to the rotation of the first rotating wheel based on information associated to the position detection signal, the synchronization being performed from a zero speed, up to a full operating speed at which processing operations are designed to be performed.

11. The method according to claim 10, comprising synchronizing, by the at least one control unit, the rotation of the second rotating wheel with respect to the rotation of the container-forming machine, at the zero speed of the container-forming machine, so as to allow the container-forming machine and the container-filling machine to run synchronized during a testing procedure.

12. The method according to claim 10, comprising synchronizing, by the at least one control unit of the container-filling machine, the rotation of the second rotating wheel with respect to the rotation of the container-forming machine, at the zero speed of the container-forming machine, during restart of the processing operations after a fault has been detected at the container-forming machine.

13. The method according to claim 12, comprising:

after detecting a fault in the container-forming machine, controlling discharge of containers from the second rotating wheel;

stopping operation of the container-filling machine;

after the fault in the container-forming machine has been corrected, synchronizing at the zero speed of the container-forming machine, the rotation of the container-filling machine to the motion of the container-forming machine, using the information associated with the position detection signal from the position sensor of the container-forming machine; and

restarting operation of the container-forming machine (22) and the container-filling machine and controlling synchronized ramp-up to the full operating speed.

14. The method according to claim 10, comprising synchronizing, by the at least one control unit, the rotation of the second rotating wheel with respect to the rotation of the container-forming machine, at the full operating speed, during restart of the processing operations after a fault has been detected at the container-filling machine.

15. The method according to claim 14, wherein the container-forming machine is a blow-moulding machine configured to form containers starting from preforms;

the method further comprising;

after detecting a fault in the container-filling machine, controlling discharge of preforms and containers from the first rotating wheel of the container-forming machine, which continues to run at the full operating speed;

after the fault in the container-filling machine has been corrected, restarting operation of the container-filling machine, and loading again preforms on the first rotating wheel of the container-forming machine;

synchronizing at the full operating speed, the rotation of the container-filling machine to the motion of the container-forming machine, using the information associated with the position detection signal from the position sensor of the container-forming machine.

16. The method according to claim 10, wherein the information associated with the position detection signal includes a position and a speed of rotation of the first rotating wheel around the first rotation axis.

17. The method according to claim 10, wherein the container-filling machine further includes a number of transfer star wheels designed to transfer containers, coupled to the second rotating wheel;

the method comprising generating a virtual rotation axis based on the information associated with the position detection signal and controlling rotation of the second rotating wheel and the transfer star wheels according to the generated virtual rotation axis.

18. A container-processing plant comprising:

a container-forming machine configured to form a container, the container-forming machine having a first rotating wheel for rotating the container about a first rotation axis;

a container-filling machine operatively coupled to the container-forming machine and configured to fill the container, the container-filling machine having a second rotating wheel for rotating the container about a second rotation axis;

at least one electric motor configured to cause the first rotating wheel and the second rotating wheel to rotate, the synchronization system comprising;

a position sensor provided in the container-forming machine and configured to detect a rotating position of the first rotating wheel and to generate a position detection signal;

at least one control unit configured to;

receive information associated with the position detection signal;

synchronize the rotation of the second rotating wheel to the rotation of the first rotating wheel based on the information associated with the position detection signal; and

synchronize the rotation of the container-forming machine and container-filling machine from a zero speed up to a full operating speed of the container forming machine at which processing operations are designed to be performed.