Patent Application
20070294040
A better understanding of the exemplary embodiments of the present invention (including alternatives and/or variations thereof) may be obtained with reference to the detailed description of the exemplary embodiments along with the following drawings, in which:
Referring now to the schematic representation of a molding system 100 as illustrated in
A clamp is illustrated as 102. The clamp includes a pair of platens 103, 105 to receive a mold 104. A drive 120 provides operational power to translate a moving platen 103 and to provide clamp tonnage. The drive 120 may be electric, hydraulic, or a combination of hydraulic and electric.
The mold 104 includes a hot half 104B and a cold half 104A and provides at least one core and cavity (not shown) to form a molded part. Optionally, the mold 104 includes a hot runner 106 for distributing melt within the mold 104. The hot runner 106 includes electrical heaters (not shown) for keeping a melt at an elevated temperature.
A power pack 110 is provided for the molding system 100. The power pack 110 includes a control system 114 to control the molding system 100, a hydraulic portion 112 to provide hydraulic power (if hydraulics are required). Preferably, the control system is an Intel® based computer with a Windows® based operating system such at the Husky® Polaris® Control System. Optionally, in the case of an all electric molding system 100, a hydraulic portion 112 is not required. The power pack 110 also includes electrical components (not shown) and circuitry 116.
The molding system 100 includes a connection to a supply 122. The supply 122 provides electrical power and chilled water to the molding system 100. Optionally, the chilled water may be applied to keep other devices cool, for example electric motors and electrical components (not shown).
In operation of the molding system 100, raw material 124 is feed into the injection unit 108. The injection unit creates a shot of melt. The clamp 102 closes the mold 104 and then applies tonnage to the mold 104. The injection unit 108 injects the shot of melt into the mold 104. When the formed part 126 is cooled, it is removed from the mold 104 and the process repeats.
Molding systems 100 are designed to run 7 days a week 24 hours a day producing molded parts, for example PET performs, or automotive parts. For example, a PET perform system may have the capability to produce 192 preforms every 15 seconds and an unscheduled down-time can have a significant financial impact to business. At the same time, known periodic maintenance can be planned for during an active production run and preventative maintenance can take advantage of known or scheduled down-times.
Referring now to
The injection unit 108 also includes sensors 204 along a length of the barrel 109 for sensing temperature. The sensors 204 are also capable of measuring voltage, and current supplied to the electrical barrel heaters.
The injection unit 108 also includes pressure sensors 206 located upon a length of the barrel 109 to indicate pressure in the barrel 109, and pressure differentials before and after the check valve (not shown) located on the screw (not shown) and within the barrel 109 of the injection unit 108. Sensors 210 could also measure resin viscosity.
Sensors 200 determine the dryness of the raw material that is provided into a feed throat (not shown) of the injection unit 108. Sensors 212 could also measure the ambient air temperature and humidity (the operating environment around the molding system). Different raw materials require a different dryness in order to be processed and provide a good quality part.
Sensors 208 monitor the temperature and flow rate of the supplied chilled water. Sensors 214 could also monitor the physical properties of chilled water. In addition, sensors 216 could monitor voltage and current of the supplied power.
Sensors 200, 208, and 212 are intended to monitor external factors that could lead to damage of the molding system 100, components, or molded parts (not shown). For example, dirty electricity, voltage/current spikes, poor water quality, poor quality hydraulic oil, air quality, pollution, and dust.
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For example, if the injection unit 108 drive 118 is hydraulic, then sensors 202 could be capable to monitor temperature and pressure. If the injection unit 108 drive 118 is electric, then sensors 202 could capable to monitor temperature, voltage, and current.
If options or accessories are added to the molding system 100, then additional sensors to monitor parameters for the options or accessories could be added. For example, a visioning system (not shown) to detect problems with the molded parts 126 that in turn relates to problems with the molding system 100 or components of the molding system 100. As another example, the visioning system could detect the presence of a stringy gate which in turn relates to a potential temperature issue at a gate (not shown).
Persons skilled in the art will appreciate sensors 612 are readily available. For example, a thermocouple will sense temperature. A transducer will sense pressure. A voltmeter will sense voltage and an ammeter will sense current. In addition, persons skilled in the art will also appreciate a combination of sensors 612 could be arranged to monitor and provide unique parameters.
The real time preventive maintenance system 600 includes a comparator module 602. The comparator 602 has access to the real time threshold status 616 data and the real time operational parameters 606 as measured by the sensors 612.
The real time threshold status 616 data may include one or more of:
For example, with a particular drive, there are specifications for operating the drive under normal conditions. Optionally, there are limits (minimum and maximum) that provide a range of operational parameters for the drive. As another example, there are specifications for operating electrical heaters under normal conditions and optionally, limits (minimum and maximum) that provide a range of operational parameters for the heaters.
The real time operational parameters 606 may include real time measurements of voltage, current, pressure, temperature, humidity, acidity, alkinity, stress, strain, viscosity, fluid cleanliness, alignment, and mold part quality, amongst others, as measured in real time from the sensors 612.
Both the real time threshold status 616 data and the real time operational parameters 606 are correlated for each aspect of the molding system 100. For example, they are correlated for the injection unit 108, clamp 102, mold 104, hot runner 106, raw materials 124, and the supply 122. The data and parameters could also be correlated for additional devices and options such as post mold cooling.
The comparator 602 compares the real time operational parameters 606 with the real time threshold status 616 data to determine if a component is running within the normal range, below a minimum value, or above a maximum value, or a rate of change or frequency towards a limit.
If the comparator 602 determines the component is running below a minimum value, for the case wherein this is not allowed, the comparator 602 will trigger the indicator module 604 to indicate preventative maintenance. For the case where this is allowed for a period of time, or for a predefined number of occurrences without damage, then the comparator 602 checks the history 608 module to determine the frequency information and data to see if the maximum frequency has been exceeded and trigger the indicator module 604 to indicate preventative maintenance.
If the comparator 602 determines the component is running above a maximum value, for the case wherein this is not allowed, the comparator 602 will trigger the indicator module 604 to indicate preventative maintenance. For the case where this is allowed for a period of time, or for a predefined number of occurrences, then the comparator 602 checks the history 608 module to determine the frequency information to see if the maximum frequency has been exceeded and trigger the indicator module 604 to indicate preventative maintenance.
The indicator 604 module may send preventative maintenance information to the human machine interface screen, to a central customer computer system, or to a remote manufacturer computer system or customer service computer system. The computer system communicates through a network (wire or wireless), the internet, or an intranet. Preventative maintenance information includes, but is not limited to, customer identification, molding system identification, component identification, dates, and real time operational parameters.
The history module 608 receives real time operational parameters 606. The history module 608 builds and maintains a frequency 624 database. For example, number of times, or length of time a component may be operating below the minimum value or above the maximum value. The history module 608 also contains the limit information for the system, sub-systems, components and parts. The history 608 module also builds and maintains a trends 610 database. The trends 610 database contains trend data with respect to the operation of the molding system 100.
The updater 614 module maintains the real time threshold status 616 database and may modify the real time threshold status 616 database.
Initially, the manufacturer of a component, part, system, or sub-system provides the initial and present tense operational data such as the minimum real time threshold operational limits, the maximum real time threshold operational limits, and the normal operational range. Optionally for the minimum and maximum limits, an amount of time, or an accumulated amount of time, or a frequency of occurrence may be provided to understand when a component has been damaged, but will continue to work for some limited amount of time without immediate failure. In addition, the system indicates trends towards a failure as well as failure when it occurs. For example, a drive may be operated at maximum horse power rating for 5 minutes and 75% of maximum power continuously without damage. But, if the drive is operated a maximum horse power for 8 minutes, it will be damaged but not necessarily to the point of immediate failure. Preventative maintenance is therefore required before failure of the drive.
However, once the molding system 100 has been in operational use, the future tense of operational data may change. For example, if a particular customer is known to operate the molding system 100 aggressively, the history of customer data 620 may modify the operational data to different limits for preventative maintenance. The updater 614 is adaptive and may modify the operational data based upon the customer data 620.
The future operational data may also change based upon a geographic location. For example, if a molding system is located in a high humidity or high altitude environment, the geographic location data 622 may modify the operational data to different limits for preventative maintenance. The updater 614 may modify the operational data based upon the geographic data 622.
The updater module 614 also receives data from the frequency module 624 and the trends module 610 and is adaptive to the environment to modify the data based upon real time use of the molding system 100. For example, if an upper temperature limit was thought to be 400 degrees but later determined through use of the molding system 100 to be 350 degrees, then the real time threshold status 616 data would be updated accordingly. In addition, the updater module 614 takes customer data and geographic data to build a repository of system and component intelligence. This intelligence includes the same model of molding systems operated at different customer locations by different customers in different geographic locations.
The update module 614, associated logic, circuitry, and data may be located or integrated with component parts as well as the complete molding system. For example, a first updater module 614 may be located with a mold. A second updater module 614 could be located with a hot runner. A third updater module 614 could be located with a power pack 110. Then, the real time threshold status 616 information stays with the associated system, sub-system, or component part. If a mold 104 is removed from production, it can be re-introduced back into production with the last known operational data. In addition, if a hot runner 106 has to be refurbished, it contains the last known operational data.
The comparator 602, real time operational parameter 606 data, sensors 612, and real time threshold operational limit 616 data may be combined to form a preventative maintenance Indicator System.
In an embodiment of the invention the indicator system includes a comparator 602, at least one real time threshold operational limit 616 data, and sensors 612. The sensors provide at least one real time operational parameter 606 data. The comparator 602 comparing the at least one real time operational parameter 606 data with the at least one real time threshold operational limit 616 data to indicate operational status. The comparator indicating an out of tolerance condition if the operational status is either below a minimum real time operational limit or above a maximum real time threshold operational limit.
Additionally, historical data of real time operational parameters 608 may be available to the comparator 602.
In an embodiment of the invention, the indicator system includes a method for sampling at least one real time operational parameter 606 data from at least one sensor 612 of a molding system. Comparing the at least one real time operational parameter 606 data with at least one real time threshold operational limit 616 data to indicate operational status.
If the operational status is below a minimum real time threshold operational limit, the comparator further determines if this is not allowed or if a maximum limit has been reached and indicates preventative maintenance. In addition, if the operational status is above a maximum real time threshold operational limit, the comparator further determines if this is not allowed, or if a maximum limit has been reached and indicates preventative maintenance.
Threshold operational limit data may include at least one maximum limit and/or one minimum limit. These limits may be based upon units of time, frequency of occurrence, or other pre-defined molding system parameters.
The real time operational parameter 606 data and the real time operational threshold limit 616 data may include: voltages, currents, pressures, temperatures, humidity, acidity, alkinity, stress values, strain values, alignment information, viscosity, or molded part quality, amongst others. Additionally, the real time threshold operational limit data may include at least one of a normal operational range value, a minimum limit value, or a maximum limit value, amongst others.
The comparator 602 may indicate preventative maintenance for at least one of a molding system, a subsystem of the molding system, a component part of the molding system, auxiliary or supply systems to the molding system, injection unit, power pack, clamp, mold, hot or cold half of the mold, or the hot runner.
The real time threshold limit 616 data may pertain to at least one of the following, a particular customer, a geographic location, multiple customers, or multiple geographic locations.
The updater 614, history 608 data, frequency 624 data, trends 610 data, manufacturer 618 data, customer 620 data, and geographic location 622 data may be combined to form a preventative maintenance update system. This system keeps the real time threshold status 616 data up to date and current.
In an embodiment of the invention the apparatus for updating preventative maintenance data of a molding system includes an updater 614, and a real time threshold status 616 data. The updater having access to categories of history 608 data and the updater providing periodic updates to the real time threshold status 616 data. The updater may determine which categories are applied to update the real time threshold status 616 data. Access to history 608 data may be remote access, local access, or global access. The updater may modify at least one data parameter of the normal operational range value, or a minimum limit value, or a maximum limit value.
In an embodiment of the invention, the method for updating preventative maintenance data of a molding system includes receiving real time operational parameter 616 data and storing as history 608 data. Sorting the history 608 data into categories. Sending real time periodic updates to real time threshold status 616 data.
The apparatus for updating preventative maintenance data of a molding system may be located with one of the following to include: molding system, power pack, injection unit, clamp, mold, hot half, cold half, hot runner, control system, or a molding system component. There may be one apparatus for updating preventative maintenance data of a molding system or a plurality of apparatus for updating preventative maintenance data of a molding system distributed around the system as previously described.
The categories of history 608 data may include at least one of frequency 624 data, trends 610 data, manufacturer 618 data, and plurality of manufacturer 618 data, customer data 620, plurality of customer's 620 data, geographic location 622 data, and plurality of geographic location 622 data.
Referring now to
Upon receipt of preventative maintenance information, a general practitioner 714 customer service representative may become involved to assess the problem and take corrective action. If a general practioner 714 customer service representatives cannot resolve the problem nor take corrective action, then a specialist 718 customer service representative may become involved to assess the problem, assess the symptoms, and perform a root cause analysis to take corrective action or provide recommendations or actions to adjust the molding system process parameters. Optionally, both the general practitioner 714 and the specialist 718 have access to customer's molding systems 100 through a remote control and diagnostic system 716 such as the Husky® ServiceLink™ technology. The ServiceLink™ technology provides a connection from a remote computer through a network/internet connection into the Polaris® molding system 100 control system.
A service scheduler 702 receives the preventative information from the preventative maintenance 700 module. This may occur automatically to schedule preventative maintenance or may occur as a result of a customer service representative. The service scheduler 702 attempts to align preventative service with known customer down time or service time. For example, fit preventative service into known gaps in production cycles, or within scheduled down times. Essentially, create a match between the service provider and the customer when the service provider has personnel and parts ready at the same time the customer is not in an active production run.
Service events and planning include upgrades, a change part date, scheduled service, and production cycle scheduled down time.
In summary, when an out of tolerance condition is detected by the comparator 602 which could lead to an instability or failure of the molding system 100, preventative maintenance of this issue is scheduled into the next available service event.
A parts system 708 also receives preventative maintenance information. The parts system 708 ensures an available supply of parts through inventory management 712. In addition, an inventory location 710 module ensures parts are either stored in a central repository, or a distributed repository based upon the geographic or customer information provided with the preventative maintenance information. The inventory management 712 module may also interact with other vendors and supply chain management software to better predict a supply of spare parts based upon the frequency and trend data available in the preventative maintenance information.
A business system 706 provides the necessary financial and business level support as a result of the customer service and spare parts activity with a customer.
The preventative maintenance 700 logic, business system logic 706, service scheduler 702 logic and parts system 708 logic may be grouped to form a preventative maintenance system for a molding system.
In an embodiment of the invention, the preventative maintenance 700 logic may communicate an indication for preventative maintenance to a general practioner 714 for resolution. The general practioner 714 in turn may transfer the indication for preventative maintenance to a specialist. Alternatively, the preventative maintenance 700 log may communicate an indication for preventative maintenance directly to a specialist 718.
Both the general practioner 714 and specialist 718 may have access to remote control 716 logic for inspecting, or resolving the need for preventative maintenance. Confirmation may be passed back to the preventative maintenance 700 logic.
The preventative maintenance 700 logic may communicate with business system 706 logic for invoicing and billing.
The preventative maintenance 700 logic may also communicate with service scheduler 702 logic to schedule service. Scheduling service may be based upon fit into a service provider's schedule, or fit to a customer schedule, or fit to a per-determined existing customer maintenance schedule, or fit to availability of service personnel, or fit to the availability of service parts.
The preventative maintenance 700 logic may also communicate with parts management logic to manage parts inventory with either a central parts inventory or a distributed parts inventory.
In an embodiment of the invention, the method for real time preventative maintenance of a molding system includes indicating an out of tolerance condition based upon a real time operational status, and creating a notice for preventative maintenance.
The notice of preventative maintenance may be communicated directly to either a customer system of a service provider system. The customer system in turn may communicate with the service provider system.
The preventative maintenance system may send communications to either a general practioner or a specialist for resolution. Either of the general practioner or specialist may have remote access and control of the molding system for conducting a preventative maintenance inspection and they may communicate the need for preventative maintenance.
The preventative maintenance system may communicate with a service scheduler to schedule maintenance. The scheduler may determine a fit to a service provider's schedule, or fit to a customer schedule, or a pre-determined existing maintenance schedule, or fit to availability of service personnel, or fit to availability of service parts.
The preventative maintenance system may communicate with a parts system for inventory management to provide a central parts inventory or a distributed parts inventory.
The preventative maintenance system may also communicate with a business system for invoicing and billing.
In an embodiment of the invention, the real time preventative maintenance system 600 is embodied in the control system 114 of a molding system 100. Alternatively, it may be embodied as a stand alone system at a customer's factory. Alternatively, it may be embodied as a stand alone system at an equipment manufacturer's site providing customer service. Alternatively, it may be partially embodied in the control system 114 of a molding system 100 and interacting with other software systems distributed at a customer site or a manufacturer's site. The real time preventative maintenance system 600 may be implemented in hardware, firmware, software or a combination of hardware, firmware, and software. Persons skilled in the art will also appreciate that the preventative maintenance system 600 may be a single integrated system, or a distributed system, with one or many software/firmware modules, with one or many hardware components and one or many integrated or separate databases.
The description of the exemplary embodiments provides examples of the present invention, and these examples do not limit the scope of the present invention. It is understood that the scope of the present invention is limited by the claims. Having thus described the exemplary embodiments, it will be apparent that modifications and enhancements are possible without departing from the concepts as described.
