WO2007149786A2 - Système et procédé de connexion intelligente - Google Patents

Système et procédé de connexion intelligente Download PDF

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Publication number
WO2007149786A2
WO2007149786A2 PCT/US2007/071384 US2007071384W WO2007149786A2 WO 2007149786 A2 WO2007149786 A2 WO 2007149786A2 US 2007071384 W US2007071384 W US 2007071384W WO 2007149786 A2 WO2007149786 A2 WO 2007149786A2
Authority
WO
WIPO (PCT)
Prior art keywords
station
vacuum
smart connection
hose
output line
Prior art date
Application number
PCT/US2007/071384
Other languages
English (en)
Other versions
WO2007149786A3 (fr
Inventor
Michael J. Rasner
Original Assignee
Crg Logics
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Crg Logics filed Critical Crg Logics
Priority to US12/305,339 priority Critical patent/US20090320946A1/en
Publication of WO2007149786A2 publication Critical patent/WO2007149786A2/fr
Publication of WO2007149786A3 publication Critical patent/WO2007149786A3/fr

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Classifications

    • 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
    • B29C31/00—Handling, e.g. feeding of the material to be shaped, storage of plastics material before moulding; Automation, i.e. automated handling lines in plastics processing plants, e.g. using manipulators or robots
    • B29C31/04—Feeding of the material to be moulded, e.g. into a mould cavity
    • B29C31/10—Feeding of the material to be moulded, e.g. into a mould cavity of several materials
    • 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
    • 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
    • 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
    • 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
    • B29B7/80—Component parts, details or accessories; Auxiliary operations
    • B29B7/86—Component parts, details or accessories; Auxiliary operations for working at sub- or superatmospheric pressure
    • 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
    • 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
    • B29C48/29—Feeding the extrusion material to the extruder in liquid form
    • 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
    • B29C48/286—Raw material dosing
    • 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
    • B29C48/297—Feeding the extrusion material to the extruder at several locations, e.g. using several hoppers or using a separate additive feeding
    • 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
    • B29K2105/0005—Condition, form or state of moulded material or of the material to be shaped containing compounding ingredients
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T137/00—Fluid handling
    • Y10T137/8593—Systems
    • Y10T137/87571—Multiple inlet with single outlet
    • Y10T137/87676—With flow control

Definitions

  • This invention relates generally to devices, systems and methods used in the bulk products industry and has specific application in the plastic extrusion industry for the fabrication of extruded plastic products. More specifically, the claimed invention relates to a system and method for sequencing draws on a given plastic resin line used in an extrusion production set-up, thus preventing two vacuum pumps from pulling on the same line at the same time and eliminating the need for multiple resin lines for each ingredient. It also relates specifically to such a system and method where cross-checking of material connections can be made for desired resin blending, or "recipes.”
  • raw plastic material in the industry, is melted and formed into a continuous profile. Extrusion produces items such as piping, tubing, window frames, and the like, hi the extrusion of plastics, raw thermoplastic materials in the form of small pellets of resin are used to make the plastic end-product.
  • the pellets start out in a product supply container, such as a silo or gaylord box.
  • a pneumatic system is used to move the plastic pellets from the supply container to one or more weigh hoppers. Pellets are dispensed from the weigh hoppers into a blender where pellets of different types, i.e.
  • the "ingredients" for the recipe, and in pre-determined quantities, are combined to produce the end product in accordance with the pre-determined product recipe.
  • Additives such as colorants and ultraviolet inhibitors, for example, which are also distributed in pellet form, can be dispensed in like fashion.
  • the ingredients enter the feed throat of a plastic extruder, the feed throat being disposed to one end of the extruder.
  • the ingredients then come into contact with a rotating screw which forces the pellets through a barrel within which the screw is rotating.
  • the barrel is heated to a desired temperature which allows the pellets to melt gradually as they are pushed through the barrel. Extra heat is contributed by the intense pressure and friction that takes place within the barrel.
  • the molten plastic enters a die, which gives the final product its profile.
  • the plastic exits in continuous form to be cut in lengths or coiled, depending upon the end product desired.
  • the raw material i.e. the resin pellets
  • the raw material i.e. the resin pellets
  • This is typically accomplished through the use of pneumatic systems having vacuum pumps that move the pellets through and along vacuum lines and the like.
  • the trend in the plastic extrusion industry today is to provide more layers and more additives for each "blend" or recipe that is used for the fabrication of a particular product, hi the experience of this inventor, it is not uncommon for one extrusion line to have nine or more extruders with as many as six blend components at each extruder. Additionally, most extrusion processing factories are doing shorter runs which results in more product changeovers.
  • the extrusion processors can run any of the ingredients in any of the extruders. As mentioned above, these ingredients typically come from either a silo or a gaylord box. It is common practice in the extrusion industry to run a common resin, or ingredient, line with drops to multiple locations. This industry trend presents some problems for plastic extrusion converting factories.
  • the first problem relates to piping complexity. When there are multiple vacuum pumps required on the extrusion line, both pumps can't draw on the same resin line at the same time. Historically, there was no way of knowing which line was connected where and this presented a problem. The solution was to run a common resin line from each of the ingredient locations for every pump that was required on the extrusion line. Typical is two pumps and this means two sets of ingredient lines for each ingredient. There can be ten or more silo ingredients and fifteen or more box ingredients. This presents a piping challenge in both real estate and cost.
  • the second problem relates to connection errors.
  • Errors can cost extrusion processors tens of thousands of dollars in waste and lost production time. The costs increase exponentially if a "bad" product, i.e. a product fabricated with incorrect ingredients, makes it to the end user or to another step of the converting process.
  • a "programmable automation controller” also known as a “programmable logic controller” or “PLC”
  • PLC programmable logic controller
  • the system and method of the claimed invention also solves the "connection error" problem mentioned above. Since the PLC knows which ingredient is connected to which blend component on which extruder, the PLC "logic" can perform a cross-check of the material connections versus the desired recipe.
  • Fig. 1 is a plan view of an exemplary extrusion line installation using the system and method of the claimed invention.
  • Fig. 2 is a side elevational view of a portion of the system that is constructed in accordance with the claimed invention.
  • Fig. 3 is a graphical representation of a first user screen display that could be used with the system and method of the claimed invention.
  • Fig. 4 is a graphical representation of a second user screen display that could be used with the system and method of the claimed invention.
  • Fig. 5 is a detailed drawing of the male end of the smart connection hose.
  • Fig. 6 is a detailed drawing of the female end of the smart connection hose.
  • DETAILED DESCRIPTION Referring now to Fig. 1 , a possible configuration using the smart system and method of the claimed invention is shown in detail.
  • Fig. 1 shows one possible installation of the smart system 10 at two levels. More specifically, Fig. 1 shows a high level extruding plant layout diagram with capacity for expansion.
  • Fig. 1 shows a system comprising twenty-four (24) sources for resin, twenty (20) being from silos 3 and four (4) from Gaylord bins 2, although the amount of resin sources employed is not a limitation of the claimed invention.
  • Vacuum lines 4 from each silo 3 or Gaylord bin 2 direct product to a plurality of product lines.
  • Each product line contains three smart systems 10.
  • Each of the smart systems 10 shown has twenty- four (24) shared input lines and either six (6) or seven (7) output lines 30.
  • the output lines 30 direct bulk product from the smart system 10 to vacuum receivers 40.
  • the vacuum receivers 40 provide short-term material storage. Each vacuum receiver 40 is connected, via conduit, to a pneumatic manifold 6. The pneumatic manifolds 6 are connected to vacuum lines 9 which are, in turn connected to vacuum pumps 2. In the given configuration, by sequencing draws on various lines, four (4) vacuum pumps maintain a supply of bulk product at seventy-six (76) vacuum receiver 40 locations.
  • the smart system 10 is controlled by programmable logic controller (PLC) (not shown) such that the vacuum receivers 40 each contain adequate supply of short term storage for eventual delivery to the blenders 7 to make an intermediate or final product.
  • PLC programmable logic controller
  • the PLC is in electronic communication with the pneumatic manifolds 6 as well as level sensors (not shown) within the vacuum receivers 40. When a level sensor detects a need for further bulk product, the level sensor sends a signal to the PLC which controls the appropriate pneumatic manifold to resupply the vacuum receiver 40.
  • Fig. 2 it will be seen that one embodiment of a configuration using the smart system and method 10 of the claimed invention is illustrated in more detail.
  • the system and method of the claimed invention includes two components.
  • the first component is the mechanical component.
  • the second component is the electrical component.
  • a hose fed from the vacuum receiver station or blender with integral vacuum receivers.
  • This hose has a wire that feeds to the male end of the connection.
  • the male end contains a termination point for the wire (this is the signal wire used by the PLC for determining that the connection is or is not made) and also the ground wire for the grounded resin flexible hose, or "flex hose.” It is common practice to ground the flex hose to prevent static electricity build-up. The system simply accounts for this in the connection as a standard precaution.
  • the female end of the connection point is contained in a connection stand.
  • the connection contains a device that makes electrical continuity with the male end for passing the signal.
  • the female connection is then wired back to a junction box and fed back to the PLC.
  • the PLC sends an output that feeds from the vacuum receiver side of the connection hose. That output is then received back to the PLC as an input. There is an input designated for each of the possible material connections. There is an output for each of the possible vacuum receivers.
  • the PLC sequences through each output and determines which input turned on to determine the physical connections. This scenario is true for each of the possible extruders.
  • There is a material manager screen where the user enters a list of materials and defines which ingredients are in which silo and which ingredient is in which box ingredient line.
  • the PLC (which is controlling the pump sequencing) sequences draws on the material line preventing simultaneous draws on an individual line.
  • the PLC also verifies the actual connections to the desired recipe. If they don't match the system will alarm and can also provide a "lock-out" function to prevent the machine from running.
  • the embodiment of the system includes two hoses 30, 30a that are from the vacuum receiver station 40 (or blender with integral vacuum receivers) and are connected to it at one end 36. It is to be understood that any number of like-constructed flexible hoses could be used in this or other embodiments, the number of hoses not being a limitation of the claimed invention.
  • Each hose 30, 30a has a wire 31, shown in more detail in Fig. 5 that feeds to the male end 32, 32a of the connection 34, 34a.
  • the male end 32, 32a contains a termination point for the wire 31.
  • the connection is a shallow cup-like structure. Disposed within the center of the cup-like structure and extending outwardly from the bottom of the cup- like structure is the tube-like connection 34, 34a. Disposed between the outer perimeter of the tube-like connection 34, 34a and the lip of the cup-like structure of the male end 32, 32a is a conductive copper ring (also not shown).
  • the termination point for the wire that is contained within the flex hose 30, 30a attaches to the copper ring at a point to make the copper ring part of the electrical continuum.
  • the wire 31 within the flex hose 30, 30a is the signal wire used by the PLC (not shown) for determining that the connection is or is not made and is also the ground wire for the grounded hose 30, 30a.
  • connection stand 20 The female end 23, 25, 27 of the wire connection point is contained in a connection stand or station 20.
  • the wire connection point 50 comprises a device that makes electrical continuity with the copper ring of the male end 32, 32a for passing the signal.
  • the connection stand includes a plurality of lines, including additive lines 22, resin lines 24 and silo lines 26.
  • additive lines 22, resin lines 24 and silo lines 26 the precise number of such lines is not a limitation of the system and method of the claimed invention. It should be noted, however, that each line 22, 24, 26 corresponds to a female end 23, 25, 27, respectively, that is disposed within the face 21 of the station 20.
  • the female connection is a small, spring-loaded bronze pin 51 which engages the copper ring of the male end 32, 32a of the hose 30, 30a, respectively, when the male end 32, 32a is properly secured.
  • the female end 23, 25, 27 is a flange-like device that is covered by the cup-like male end 32, 32a of the hose 30, 30a when properly placed and connected.
  • the female ends 23, 25, 27 also include a cylindrical bore 52into which the tube-like connection 34, 34a of the male end 32, 32a is slidingly received, the cylindrical bore having a slightly larger inner diameter than the outer diameter of the tube-like connection 34, 34a.
  • Means for securing the connection may be provided by, for example, spring clips (not shown) to either side of the flange at each female end 23, 25, 27.
  • Other means for securing the connection could be provided without deviating from the scope of the claimed invention.
  • an "insert and turn" L-shaped slot could be defined within the female end 23, 25, 27 as could other design alternatives known to those in the art.
  • the female connection is then wired back to a junction box and fed back to the PLC.
  • the PLC sends an output that feeds from the vacuum receiver side 23, 25, 27 of the connection hose 30, 30a. That output is then received back to the PLC as an input. There is an input designated for each of the possible material connections. There is also an output for each of the possible vacuum receivers 40. The PLC sequences through each output and determines which input turned on to determine the physical connections. This scenario is true for each of the possible extruders 60 that would be used with the system and method of the claimed invention. There is a material manager screen (not shown), such as a touch-screen panel of known technology, where the user enters a list of materials and defines which ingredients are in which silo line 26 and which ingredient is in which box ingredient line 24.
  • the user screen display could identify any number of materials and associate each with a number, the number and material each having a unique name and specific gravity.
  • the material number could be downloaded as part of the recipe download for each bin.
  • the specific gravity could be optional.
  • a typical screen display could appear, for example, as is shown in Fig. 2 and/or Fig. 3. The exact format of the screen display is not, however, a limitation of the claimed invention.
  • the PLC (which is controlling the pump sequencing) sequences draws on the material line 22, 24, 26 thereby preventing simultaneous draws on an individual line.
  • the PLC also verifies the actual connections to the desired recipe. If they don't match, the system 10 will alarm the user that there is an improper connection.
  • the system 10 can also provide a "lock-out" function to prevent the machine from running until the proper connection is made.
  • the PLC would allow the material blending and extrusion process to commence only upon a proper sequence of material "hook-ups.” In this fashion, where very sophisticated piping arrangements are used for certain applications and where there are literally thousands of combinations of connections that can be made, there is no room for human error. Errors that could otherwise cost extrusion processors tens of thousands of dollars in waste and lost production time are thus eliminated. Additionally, the costs related to extruding a "bad" product, i.e. a product fabricated with incorrect ingredients, are eliminated as well, thus insuring that a properly blended product is provided to the end user.

Abstract

La présente invention concerne un système de transfert pondéreux qui réduit la complexité de la tuyauterie et qui élimine toute possibilité d'erreurs de connexion se produisant au cours du transfert de matériaux vers une destination en aval. Le système de transfert pondéreux utilise un automate programmable industriel (A.P.I.) pour vérifier que la ligne de sortie correcte est utilisée. En outre, l'A.P.I. ordonne les amenées de matériau de telle sorte qu'il est possible d'utiliser moins de pompes afin de déplacer la même quantité de matériau vers sa destination.
PCT/US2007/071384 2006-06-17 2007-06-15 Système et procédé de connexion intelligente WO2007149786A2 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
US12/305,339 US20090320946A1 (en) 2006-06-17 2007-06-15 Smart connection system and method

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US81416106P 2006-06-17 2006-06-17
US60/814,161 2006-06-17

Publications (2)

Publication Number Publication Date
WO2007149786A2 true WO2007149786A2 (fr) 2007-12-27
WO2007149786A3 WO2007149786A3 (fr) 2008-08-07

Family

ID=38834273

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US2007/071384 WO2007149786A2 (fr) 2006-06-17 2007-06-15 Système et procédé de connexion intelligente

Country Status (2)

Country Link
US (1) US20090320946A1 (fr)
WO (1) WO2007149786A2 (fr)

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20120174336A1 (en) * 2011-01-12 2012-07-12 Nyakatura Francis E Automated Wand System

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US3719214A (en) * 1970-07-09 1973-03-06 Precision Metalsmiths Inc Investing apparatus
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US7147012B2 (en) * 2003-10-30 2006-12-12 Fluid Management, Inc. Combination gravimetric and volumetric dispenser for multiple fluids
US7189345B2 (en) * 2003-08-13 2007-03-13 The Boeing Company Method for vacuum assisted resin transfer molding

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Publication number Priority date Publication date Assignee Title
US3719214A (en) * 1970-07-09 1973-03-06 Precision Metalsmiths Inc Investing apparatus
US6168408B1 (en) * 1997-03-24 2001-01-02 Aerospatiale Societe Nationale Industrielle Apparatus for manufacturing composite parts produced by resin transfer molding
US7189345B2 (en) * 2003-08-13 2007-03-13 The Boeing Company Method for vacuum assisted resin transfer molding
US7147012B2 (en) * 2003-10-30 2006-12-12 Fluid Management, Inc. Combination gravimetric and volumetric dispenser for multiple fluids

Also Published As

Publication number Publication date
US20090320946A1 (en) 2009-12-31
WO2007149786A3 (fr) 2008-08-07

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