WO2010031159A1

WO2010031159A1 - A method of operating a molding system

Info

Publication number: WO2010031159A1
Application number: PCT/CA2009/001179
Authority: WO
Inventors: Jean-Christophe Witz; Laurent Christel Sigler
Original assignee: Husky Injection Molding Systems Ltd.
Priority date: 2008-09-17
Filing date: 2009-09-01
Publication date: 2010-03-25

Abstract

According to embodiments of the present invention, there is provided a method and system for operating a molding system (100). The molding system (100) includes a molding system component (118) associated with a memory entity (202), the molding system further including a memory reader entity (204) configured to communicate with the memory entity (202), the method being executable at a controller (180) of the molding system (100). The method (300) comprises the step of appreciating (320) from the memory reader entity (204) a data element associated with the memory entity (202), the data element being representative of a number of cycles undergone by the molding system component (118); responsive to the number of cycles not conforming to a pre-determined threshold, generating (330) a command signal, the command signal comprising at least one adjusted operational parameter for causing change in execution of at least one routine performed by the molding system (100), the change in execution of the at least one routine for preventing damage to the molding system (100).

Description

A METHOD OF OPERATING A MOLDING SYSTEM

FIELD OF THE INVENTION

The present invention generally relates to, but is not limited to, molding systems, and more specifically the present invention relates to, but is not limited to, a method of operating a molding system.

BACKGROUND OF THE INVENTION

Molding is a process by virtue of which a molded article can be formed from molding material by using a molding system. Various molded articles can be formed by using the molding process, such as an injection molding process. One example of a molded article that can be formed, for example, from polyethylene terephthalate (PET) material (or other suitable materials) is a preform that is capable of being subsequently blown into a beverage container, such as, a bottle and the like.

As an illustration, injection molding of PET material involves heating the PET material to a homogeneous molten state and injecting, under pressure, the so-melted PET material into a molding cavity defined, at least in part, by a female cavity piece and a male core piece mounted respectively on a cavity plate and a core plate of the mold. The cavity plate and the core plate are urged together and are held together by clamp force, the clamp force being sufficient enough to keep the cavity and the core pieces together against the pressure of the injected PET material. The molding cavity has a shape that substantially corresponds to a final cold-state shape of the molded article to be molded. The so-injected PET material is then cooled to a temperature sufficient to enable ejection of the so-formed molded article from the mold. When cooled, the molded article shrinks inside of the molding cavity and, as such, when the cavity and core plates are urged apart, the molded article tends to remain associated with the core piece. Accordingly, by urging the core plate away from the cavity plate, the molded article can be demolded, i.e. ejected off of the core piece. Ejection structures are known to assist in removing the molded articles from the core halves. Examples of the ejection structures include stripper plates, ejector pins, robots, etc. Various components of the molding system may have different life cycle spans. Accordingly, some of the components of the molding system may become worn out much sooner than others of the components of the molding system. If the entity operating the molding system does not appreciate that some of the components are worn out and require replacement (and actually replaces them in good time), performance of the molding system may be adversely impacted and, in an extreme case may result in damage to the molding system and the associated lengthy and costly repairs.

US patent application 2005/0053684 to Pitscheneder et al. published on March 10, 2005 discloses an injection molding system with a mold that can be opened and closed, into the mold cavity of which a fluid molding compound, preferably plastic, can be injected, and with at least one reading device (12) for at least one transponder (13) arranged in the mold cavity (4).

SUMMARY OF THE INVENTION

According to a first broad aspect of the present invention, there is provided a method of operating a molding system, the molding system including a molding system component associated with a memory entity, the molding system further including a memory reader entity configured to communicate with the memory entity, the method executable at a controller of the molding system. The method comprises appreciating from the memory reader entity a data element associated with the memory entity, the data element being representative of a number of cycles undergone by the molding system component; responsive to the number of cycles not conforming to a pre-determined threshold, generating a command signal, the command signal comprising at least one adjusted operational parameter for causing change in execution of at least one routine performed by the molding system, the change in execution of the at least one routine for preventing damage to at least a portion of the molding system.

According to a second broad aspect of the present invention, there is provided a molding system. The molding system comprises a molding system component; a memory entity associated with the molding system component; a memory reader entity configured to communicate with the memory entity; a controller being operable to communicate with the memory reader entity and to control at least one routine executed within the molding system; the controller being further operable: to appreciate from the memory reader entity a data element associated with the memory entity, the data element being representative of a number of cycles undergone by the molding system component; responsive to the number of cycles not conforming to a pre-determined threshold, to generate a command signal, the command signal comprising at least one adjusted operational parameter for causing change in execution of the at least one routine performed by the molding system, the change in execution of the at least one routine for preventing damage to at least a portion of the molding system.

These and other aspects and features of non-limiting embodiments of the present invention will now become apparent to those skilled in the art upon review of the following description of specific non-limiting embodiments of the invention in conjunction with the accompanying drawings.

DESCRIPTION OF THE DRAWINGS

A better understanding of the 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:

Figure 1 is a schematic representation of a molding system 100 that can be adapted to implement embodiments of the present invention. Figure 2 depicts a portion of the molding system 100 of Figure 1, the portion implemented in accordance with a non- limiting embodiment of the present invention.

Figure 3 depicts a flow chart of a method of operating the molding system 100 of Figure 1, the method implemented in accordance with a non-limiting embodiment of the present invention.

The drawings are not necessarily to scale and are may be illustrated by phantom lines, diagrammatic representations and fragmentary views. In certain instances, details that are not necessary for an understanding of the exemplary embodiments or that render other details difficult to perceive may have been omitted.

DETAILED DESCRIPTION OF EMBODIMENTS

With reference to Figure 1, there is depicted a non-limiting embodiment of a molding system 100 which can be adapted to implement embodiments of the present invention. For illustration purposes only, it shall be assumed that the molding system 100 comprises an injection molding system for processing molding material, such as, PET for example into preforms suitable for subsequent blow-molding. However, it should be understood that in alternative non-limiting embodiments, the molding system 100 may comprise other types of molding systems, such as, but not limited to, plastic injection molding system, plastic compression molding systems, metal molding systems and the like. It should be further understood that embodiments of the present invention are applicable to the molding system 100 incorporating any multicavitation mold, including PET molds, thinwall articles molds, closures molds and the like. Finally, it should be understood that embodiments of the present invention are also applicable to upstream and/or downstream equipment associated with the molding system 100 (just as example, PET dryers, preform handling equipment, etc.).

Within the non-limiting embodiment of Figure 1, the molding system 100 comprises a fixed platen 102 and a movable platen 104. The molding system 100 further comprises an injection unit 106 for plasticizing and injection of molding material (such as, in this case, PET). In operation, the movable platen 104 is moved towards and away from the fixed platen 102 by means of stroke cylinders (not shown) or any other suitable means. Clamp force (also referred to as closure, clamp or mold closure tonnage) can be developed within the molding system 100, for example, by using tie bars 108, 110 and a tie-bar clamping mechanism 112, as well as (typically) an associated hydraulic system (not depicted) that is usually associated with the tie-bar clamping mechanism 112. It will be appreciated that clamp tonnage can be generated using alternative means, such as, for example, using a toggle-clamp arrangement (not depicted) or the like.

A first mold half 114 can be associated with the fixed platen 102 and a second mold half 116 can be associated with the movable platen 104. In the specific non-limiting embodiment of Figure 1, the first mold half 114 comprises one or more mold cavities 118. As will be appreciated by those of skill in the art, the one or more mold cavities 118 may be formed by using suitable mold inserts or any other suitable means. As such, the first mold half 114 can be generally thought of as a "mold cavity half. In some embodiments of the present invention, the first mold half 114 can be associated with a hot runner, which is not depicted but very well known to those of skill in the art.

The second mold half 116 comprises one or more mold cores 120 complementary to the one or more mold cavities 118. As will be appreciated by those of skill in the art, the one or more mold cores 120 may be formed by using suitable mold inserts or any other suitable means. As such, the second mold half 116 can be generally thought of as a "mold core half.

The first mold half 114 can be coupled to the fixed platen 102 by any suitable means, such as a suitable fastener (not depicted) or the like. The second mold half 116 can be coupled to the movable platen 104 by any suitable means, such as a suitable fastener (not depicted) or the like.

It should be understood that in an alternative non-limiting embodiment of the present invention, the position of the first mold half 114 and the second mold half 116 can be reversed and, as such, the first mold half 114 can be associated with the movable platen 104 and the second mold half 116 can be associated with the fixed platen 102.

In an alternative non-limiting embodiments of the present invention, the fixed platen 102 need not be stationary and may as well be moved in relation to other components of the molding system 100.

Figure 1 depicts the first mold half 114 and the second mold half 116 in a so-called "mold open position" where the movable platen 104 is positioned generally away from the fixed platen 102 and, accordingly, the first mold half 114 is positioned generally away from the second mold half 116. For example, in the mold open position, a molded article (not depicted) can be removed from the first mold half 114 and/or the second mold half 116. In a so-called "mold closed position" (not depicted), the first mold half 114 and the second mold half 116 are urged together (by means of movement of the movable platen 104 towards the fixed platen 102) and cooperate to define (at least in part) a molding cavity (not depicted) into which the molten plastic (or other suitable molding material) can be injected, as is known to those of skill in the art. It should be appreciated that one of the first mold half 114 and the second mold half 116 can be associated with a number of additional mold elements, such as for example, split inserts (commonly referred to as "neck rings") for forming, for example, a neck area of a molded article in case of the molded article being a preform. Furthermore, the first mold half 114 and the second mold half 116 may be associated with one or more leader pins (not depicted) and one or more leader bushings (not depicted), the one or more leader pins cooperating with one more leader bushings to assist in alignment of the first mold half 114 with the second mold half 116 in the mold closed position, as is known to those of skill in the art. The molding system 100 further comprises a robot 122. It should be noted that in an alternative non-limiting embodiments of the present invention, other types of actuators can be used that may or may not include the robot 122. Generally speaking, the robot 122 can be used for molded article removal and/or post- mold cooling and/or other post-mold handling. The robot 122 can comprise an actuating portion 124, an actuating arm 125 and an End Of Arm Tool 126 (referred herein below for simplicity as EOAT 126). The actuating portion 124 is coupled to the fixed platen 102 by means of a suitable fastener (not depicted), such as suitable bolts and the like.

The molding system 100 further includes a controller generally depicted in Figure 1 at 180. The controller 180 comprises a general-purpose or a special-purpose computing apparatus that is configured to control at least some of the components of the molding system 100. To that extent, the controller 180 is programmed to generate one or more command signals to control execution of one or more routines by one or more of the components of the molding system 100. In alternative non-limiting embodiments of the present invention, the controller 180 may include more than one computing apparatus or, in other words, may be implemented in a distributed manner. In yet further non-limiting embodiments of the present invention, the controller 180 may be shared amongst the molding system 100 and other molding systems (similar or different from the molding system 100) associated with an entity managing/operating the molding system 100.

In other words, the controller 180 can act as a control/supervisory entity for more than one instance of the molding system 100. The controller 180 comprises an internal memory (not depicted, but known to those of skill in the art), which can be implemented in a variety of known ways, such as, Random Access Memory (RAM) and the like.

In some embodiments of the present invention, the controller 180 can comprise or have access to an inventory sub-system (not depicted). The inventory sub-system can be configured to store data about an inventory of spare parts in possession of an entity responsible for managing the molding system 100 or in possession of a vendor entity associated with the molding system 100.

As an example of various routines that can be controlled by the controller 180, controller 180 can be configured to control the stroke cylinder (not depicted) to implement closing and opening of the movable platen 104 relative to the fixed platen 102. More specifically, the controller 180 can control the speed of the stroke cylinder (not depicted). The controller 180 can also control the injection unit 106 and, more specifically, it can control the injection unit 106 to implement plasticizing and injection of molding material. Even more specifically, the controller 180 can control injection pressure, hold pressure, recovery time, etc. of the injection unit 106. The controller 180 can also be configured to control hydraulic system (not depicted) or other clamp force generating means to control clamp tonnage generated within the molding system 100. More specifically, the controller 180 can be configured to adjust the clamp tonnage generated within the molding system 100. Those skilled in the art will readily appreciate how the controller 180 can control various components of the molding system 100, and therefore this will not be described here at any length.

The controller 180 can control the EOAT 126 to perform one or more routines, such as: moving the EOAT 126 into an open space defined between the first mold half 114 and the second mold half 116 in the mold open position, causing the EOAT 126 to receive the molded article from the one or more mold cores 120, moving the EOAT 126 away from the open space defined between the first mold half 114 and the second mold half 116 in the mold open position, etc.

Naturally, the molding system 100 may comprise a number of additional components, such a stripper assembly for implementing (at least in part) ejection of the molded articles. Furthermore, the molding system 100 may optionally or additionally comprise auxiliary equipment (not depicted), such as driers, humidifiers, heaters and the like. Furthermore, additionally or alternatively, the molding system 100 may includes auxiliary post-mold cooling and/or handling equipment. The controller 180 may be configured (directly or via a suitable interface) to control some or all of the additional equipment potentially present within the molding system 100. All this equipment is known to those of skill in the art and, as such, will not be discussed at any length here.

It should be expressly understood that the molding system 100 may have other configurations and the description presented above has been provided as an example only and is not intended to be limiting in any form. In other non-limiting embodiments of the present invention, the molding system 100 can have other configurations with more or fewer components.

Figure 2 depicts a portion of the molding system 100 implemented in accordance with a non- limiting embodiment of the present invention. More specifically, Figure 2 depicts the first mold half 114, the EOAT 126 and the controller 180. It is noted that Figure 2 depicts these elements schematically for the sake of ease of illustration, but implementation of these components of the molding system 100 is known to those of skill in the art, as illustrated by the description of Figure 1 presented herein above. Within the illustration of Figure 2, the first mold half 114 is depicted as having 5 rows of the one or more mold cavities 118. It should be expressly understood that the number of instances of the one or more mold cavities 118 is not particularly limited and is meant to be an illustration only.

Within the embodiment being depicted herein, each of the one or more mold cavities 118 is equipped with a memory entity 202. How the memory entity 202 is coupled to the one or more mold cavities 118 is not particularly limited and is guided by consideration of operational environment, contact with the molded article being produced, etc. For example, where the one or more mold cavities 118 is implemented with mold cavity inserts, the memory entity 202 can be coupled in-between the mold cavity insert and the cavity plate housing the mold cavity insert.

It should be noted that in alternative non-limiting embodiments of the present invention, the memory entity 202 can be associated with any other component of the molding system 100, where it is desired to track the number of molding cycles and to adjust operating parameters, based on the number of molding cycles undergone by those components not conforming to the pre-determined threshold, in order to prevent damage to the molding system 100 or some or all components thereof.

For example, the memory entity 202 can be provided for each or some of what are known as "wear components", i.e. components that wear out over time and require replacement. Alternatively, the memory entity 202 can be associated with a component of the molding system 100 which is not a wear component per se, but it may be nevertheless desirable to track the number of cycles associated with such a component.

Depending on business objectives, one may choose to provide a respective memory entity (similar, for example, to the memory entity 202) in association with some or all of the following components (or portion(s) thereof) of the molding system 100: the first mold half 114; - the second mold half 116; the one or more mold cores 120; one or more neck rings (not separately numbered); one or more leader pins (not separately numbered); one or more leader bushings (not separately numbered); the EOAT 126 or components thereof; other auxiliary equipment associated with the molding system 100; one or more wedge bars (not depicted) or other locking structures (not depicted) provided for locking and/or alignment function within the molding system 100; - one or more seals (not depicted) used within the molding system (100); one or more bearings (not depicted) used within the molding system (100); one or more electronic components (not depicted) used within the molding system (100).

In some embodiments of the present invention, the memory entity 202 is implemented as a Radio Frequency Identification tag (or, simply, RFID tag), which can be a passive RFID tag, an active

RFID tag or a semi-active RFID tag. In alternative non-limiting embodiments of the present invention, the memory entity 202 is implemented as another type of a memory device. For example, in some alternative non-limiting embodiments of the present invention, the memory entity 202 can be implemented according to the WI-FI (Wireless Fidelity) standard. In yet further non-limiting embodiments of the present invention, the memory entity 202 can be implemented according to the BLUETOOTH standard. In yet further alternative non-limiting embodiments of the present invention, the memory entity 202 can be implemented based on one of a multitude of wired communication standards, such as BUS, Profibus, Universal Serial Bus (USB), RS232,

RS485 and other known standards. Naturally, where the wired communication standard is used, as will be understood by those of skill in the art, modifications will need to be made to ensure that the wiring to and from the memory entity 202 can withstand operational environment of the molding system 100, including temperature, pressure, motion, etc.

In alternative non-limiting embodiments of the present invention, only some of the one or more mold cavities 118 can be equipped with the memory entity 202. In even further non-limiting embodiments of the present invention, the first mold half 114 can be equipped with a single instance of the memory entity 202. Within these embodiments of the present invention, the memory entity 202 can be said to be "representative" of the one or more mold cavities 118.

In the specific non-limiting embodiment being presented herein, the EOAT 126 comprises a memory reader entity 204. The memory reader entity 204 is configured to communicate with the memory entity 202 (or a plurality of instances of the memory entity 202 where more than one of the one or more mold cavities 118 is equipped with the memory entity 202). In some embodiments of the present invention, where the memory entity 202 is implemented as an RFID tag, the memory reader entity 204 is implemented as an RFID tag reader. Within those embodiments, depending on the implementation of the RFID tag, the memory reader entity 204 can be configured to energize the RFID tag, to read data from the RFID tag, to record data onto the RFID tag, etc.

Even though in Figure 2, the memory reader entity 204 is depicted as a single entity, in alternative non-limiting embodiments of the present invention, the memory reader entity 204 can be implemented as a plurality of instances of memory reader entity 204, each corresponding one of the plurality of instances of the memory entity 202.

Within a specific non-limiting embodiment of the present invention to be used herein below as an illustration for Figure 2, the memory entity 202 can be implemented as a passive RFID tag. To that extent and as is known to those of skill in the art, in those embodiments of the present invention, the memory entity 202 is not associated with a dedicated power source (such as, for example, a battery) and, as such, needs to be energized by the memory reader entity 204 in order to receive or transmit data. However, in alternative non-limiting embodiments of the present invention, the memory entity 202 can be implemented as an active RFID tag and in those embodiments of the present invention, teachings to be presented herein below can be modified accordingly by one of skill in the art.

The memory reader entity 204 and the memory entity 202 are configured for a two-way communication, depicted in Figure 2 as a communication stream 206 (or, to be more precise, a plurality of instances of the communication stream 206, each being associated with a respective one of the memory entity 202). In this particular embodiment being discussed herein, the communication stream 206 is implemented as a wireless communication stream according to the RFID standard. In the embodiments of the present invention where the memory entity 202 and the memory reader entity 204 are implemented in accordance with a different standard (non- limiting examples of which are provided herein above), the communication stream 206 can be adapted to that different standard.

Examples of communication that can be carried out between the memory reader entity 204 and the memory entity 202 via the communication stream 206 include, but are not limited to: • The memory reader entity 204 interrogating the memory entity 202 for data stored in the internal memory thereof. Examples of such data include: unique identifier associated with the associated one of the one or more mold cavities 118; an indication of the number of cycles undergone by the associated one of the one or more mold cavities 118; authorization parameter associated with the associated one of the one or more mold cavities 118; process parameter associated with the associated one of the one or more mold cavities 118; and the like.

• The memory reader entity 204 transmitting a data element to the memory entity 202 for storing in the internal memory thereof. Examples of such data include: updated indication of the number of cycles undergone by the associated one of the one or more mold cavities 118; updated authorization parameter associated with the associated one of the one or more mold cavities 118; updated process parameter associated with the associated one of the one or more mold cavities 118; and the like.

Alternatively and/or additionally, where required, data communicated to/from the memory entity 202 can include appropriate security or encryption protocols, security or encryption key(s). This is particularly applicable in those embodiments of the present invention, where it is desirable to secure the communication between the memory reader entity 204 and the memory entity 202 and to prevent unauthorized access to such secure communication.

The memory reader entity 204 is further coupled to the controller 180 via a communication link 208. The communication link 208 can be implemented as a wired communication link, a wireless communication link or a combination thereof. For example, in a particular non-limiting embodiment of the present invention, the communication link 208 can be implemented as a wired communication link, implemented for example in accordance with a multitude of wired communication standards, such as BUS, Profibus, Universal Serial Bus (USB), RS232. RS485 and other known standards.

The memory reader entity 204 is configured for a two-way communication with the controller 180 via the communication link 208. Examples of communication that can be carried out between the memory reader entity 204 and the memory entity 202 include, but are not limited to:

• Data retrieved from the memory entity 202;

• Data to be stored at the memory entity 202;

• Command signals and/or data requests elements. As an example, the memory entity 202 can store an indication of a number of cycles undergone by the associated one of the one or more mold cavities 118. How this indication is generated and stored on the memory entity 202 is not particularly limited. In one example of an implementation of the present invention, the controller 180 can maintain a count of a number of molding cycles undergone by a given one of the one or more mold cavities 118 in associated with a unique identifier associated with the given one of the one or more mold cavities 118. Within these embodiments of the present invention, controller 180 can release the number of molding cycles undergone by the given one of the one or more mold cavities 118 based on the associated unique identifier. In this case, the indication of a number of cycles comprises a unique identifier which is used to look up the number of cycles and to release such the indication of the number of cycles from the controller 180. Within these embodiments of the present invention, the controller 180 can maintain an internal counter (not depicted) which can calculate the number of molding cycles associated with the one or more mold cavities 118. This internal counter may be maintained in a known manner and the controller 180 can update the count after each cycle, for example. This can be done by appreciating the identity of the one or more mold cavities 118, for example by interrogating the memory entity 202 for an associated unique identifier and incrementing the internal counter (not depicted) by the appropriate number of molding cycles (for example, if done after each molding cycle, by one).

In alternative non-limiting embodiments of the present invention, the controller 180 can cause an indication of the number of molding cycles undergone by a given one of the one or more mold cavities 118 to be stored on the associated memory entity 202. To that extent, the controller 180 can transmit a data element representative of the number of molding cycles associated with the given one of the one or more mold cavities 118 and the associated unique identifier to the memory reader entity 204 via the communication link 208. Recalling that the memory reader entity 204 can be configured for both read and write access to the memory entity 202, the memory reader entity 204 can cause the indication of the number of molding cycles to be stored on the memory entity 202 associated with the so-received unique identifier. How often this storing takes place is not particularly limiting. It is conceivable that this storing is done before, during or after each molding cycle, after a given number of hours, once a day, once a week, once a month or at any suitable time interval. Given the architecture of Figure 2, it is possible to execute a method for controlling a molding system (such as, for example, the molding system 100) according to a non-limiting embodiment of the present invention. With reference to Figure 3, a non-limiting embodiment of a method 300, implemented according to a non-limiting embodiment of the present invention, is depicted. The method 300 can be conveniently executed by the controller 180. The method 300 can be embodied in a set of commands and instructions for rendering the controller 180 operable to execute the method 300.

Step 320 - appreciating from the memory reader entity 204 a data element associated with the memory entity 202, the data element being representative of a number of cycles undergone by the molding system component

The method 300 begins at step 320, where the controller 180 appreciates from the memory reader entity 204 a data element associated with the memory entity 202, the data element being representative of a number of cycles undergone by the molding system component (for example, the one or more mold cavities 118).

In some embodiments of the present invention, the controller 180 can appreciate the data element in a "pull manner", while in other embodiments of the present invention, the controller 180 can appreciate the data element in a "push manner".

Starting with the description of the "pull manner" of obtaining the data element first, which is particularly applicable (but not limited to) in those embodiments where the memory entity 202 is implemented as a passive RFID tag and the like. The controller 180 transmits a request data element to the memory reader entity 204 via the communication link 208, this request data element configured to inter alia "energize" the memory entity 202. The request data element may include a generic request (i.e. to solicit indication of the number of molding cycles associated with all available ones of the one or more mold cavities 118) or a specific one (i.e. to solicit indication of the number of molding cycles associated with the given one of the one or more mold cavities 118, in which case such given one of the one or more mold cavities 118 is identified using the unique identifier).

Upon receipt of request data element, the memory reader entity 204 goes on to determine the indication of the number of cycles, associated with either all available ones of the one or more mold cavities 118 or a specific one based on the unique identifier. To that extent, the memory reader entity 204 interrogates either all of the available instances of the memory entity 202 (in case of the generic request) or a specific one of the available instances of the memory entity 202 (in case of the specific request) via the communication stream 206. In response to this interrogation, the memory reader entity 204 receives, from the memory entity 202 (or a plurality of instances of the memory entity 202) an indication of the number of molding cycles associated with the given one of the one or more mold cavities 118 or a plurality of indications of the number of molding cycles associated with the one or more mold cavities 118. The memory reader entity 204 then transmits the indication of the number of cycles or plurality of indications of molding cycle to the controller 180.

In those embodiments of the present invention, the memory entity 202 stores the indication of the number of molding cycles, the data element so transmitted includes the actual indication of the number of molding cycles. In those embodiments of the present invention, where the controller 180 stores the indication of the number of molding cycle, the data element transmitted from the memory entity 202 to the memory reader entity 204 via the communication stream 206 and eventually to the controller 180 via the communication link 208 can include a unique identifier of the specific memory entity 202, which can then be used by the controller 180 to look up in the internal memory (not depicted) for the associated indication of the number of molding cycles.

Now turning to the description of the "push manner" of obtaining the data element, which is particularly applicable, but not limited to, those embodiments of the present invention where the memory entity 202 is implemented as an active RFID tag or the like. In some embodiments of the present invention, the memory entity 202 can transmit, from time to time, an indication of the number of molding cycles stored thereupon. This can be done, for example, in response to detection of proximity of the memory reader entity 204.

Irrespective of whether or not the "pull manner" or the "push manner" is utilized, transmission of the indication of the number of molding cycles can be implemented at a start-up of the molding system 100. Alternatively, this transmission can be implemented at the end, during or at the beginning of each molding cycle or at certain time intervals (such as every 5 minutes, every hour, every 7 hours, every day, every week or any other suitable time interval). It should be noted that in alternative embodiments of the present invention, transmission of the request data element from the controller 180 to the memory reader entity 204 can be omitted. Within those embodiments of the present invention, the memory reader entity 204 can initiate interrogation of the memory entity 202 on its own accord.

The controller 180 then proceeds to execution of step 330.

Step 330 - responsive to the number of cycles not conforming to a pre-determined threshold, generating a command signal, the command signal comprising at least one adjusted operational parameter for causing change in execution of at least one routine by the molding system (100), the change in execution of at least one routine for preventing damage to at least a portion of the molding system (100)

Next, at step 330, the controller 180, responsive to the number of cycles not conforming to a pre- determined threshold, generates a command signal, the command signal comprising at least one adjusted operational parameter for causing change in execution of at least one routine by the molding system 100, the change in execution of at least one routine for preventing damage to at least a portion of the molding system 100.

First, as part of execution of the step 330, the controller 180 compares the indication of the number of cycles received in step 320 with the pre-determined threshold. An indication of the pre-determined threshold can be stored in the internal memory (not depicted) associated with the controller 180. In some non-limiting embodiments of the present invention, a dedicated indication of the threshold can be stored in associated with each one of the one or more mold cavities 118. In alternative non-limiting embodiments of the present invention, a single indication of the threshold applicable to all of the one or more mold cavities 118 can be stored.

If the controller 180 determines that the number of molding cycles conforms to the threshold (for example lower than the threshold), the controller 180 loops back to execution of step 320, where it awaits to appreciate another indication of the number of molding cycles.

If, on the other hand, the controller 180 determines that the number of molding cycles does not conform to the pre-determined threshold, the controller 180 goes on to generate a command signal, the command signal comprising at least one adjusted operational parameter for causing change in execution of at least one routine by the molding system 100, the change in execution of at least one routine for preventing damage to at least a portion of the molding system 100.

The controller 180 then releases the command signal towards a component of the molding system 100 associated or responsible for the at least one routine being adjusted in order to control (i.e. to adjust) execution of the at least one routine by the so-associated component of the molding system 100.

In some embodiments of the present invention, the at least one routine is the amount of clamp tonnage and within these embodiments, the command signal is for controlling the clamp tonnage. In other words, the adjusted operational parameter is adjusted clamp tonnage parameter. Within these examples, change in the clamp tonnage (for example, increasing the clamp tonnage) could be helpful in avoiding mold flash and the associated defects potentially evident on the preform.

In other embodiments of the present invention, the at least one routine is the injection pressure and/or hold pressure and within these embodiments, the command signal is for controlling the injection pressure and/or hold pressure. In other words, the adjusted operational parameter is adjusted injection and/or hold pressure parameter. Within these examples, change in the injection pressure and/or hold pressure (for example, lowering the injection pressure and/or hold pressure) can be helpful in reducing the amount of pressure applied onto the mold.

Yet in further embodiments of the present invention, the at least one routine is the speed of the stroke cylinder and within these embodiments, the command signal is for controlling the speed of the stroke cylinder either completely or during certain stages of the molding cycle (for example, during a later part of the mold closing portion of the molding cycle). In other words, the adjusted operational parameter is adjusted speed of the stroke cylinder parameter. Within these examples, change in the speed of stroke cylinder (for example, lowering the speed of stroke cylinder) can be helpful in reducing inertia during the final stages of mold closing, which in turn can be helpful in protecting the mold against impact.

One should appreciate that examples provided herein above for the type of the at least one routine and the associated command signal(s) are meant as examples only. As such operational parameters for a combination of these and/or other routines can be changed as part of implementation of embodiments of the present invention. Optional enhancements

In some embodiments of the present invention, the controller 180 can further cause a message to be conveyed to an operator of the molding system 100, the message for indicating that a given component of the molding system 100 (such as some or all of the one or more mold cavities 118) have reached their operational life threshold. The message can be an audible message, a text message in a Human Machine Interface (not depicted) of the controller 180, a combined audiovisual message or any other suitable message. Additionally or alternatively, the controller 180 can present an order message, either enabling the operator to order the replacement parts or providing instructions as to how to order the replacement parts. It is noted that either or both of these messages can be conveyed to the operator before releasing the command signal described above, concurrently with releasing the command signal described above or after releasing the command signal described above.

In further embodiments of the present invention, the controller 180 can further query the inventory sub-system (not depicted) in order to determine whether the entity responsible for managing the molding system 100 has the available spare parts that require replacement.

By the same token, the memory reader entity 204 does not have to be coupled to the EOAT 126. Rather, one or more instances of the memory reader entity 204 can be coupled to any suitable portion of the molding system 100. Those skilled in the art will appreciate that when deciding where to position the memory reader entity 204, several considerations need to be taken into account, including: (a) proximity and range of operation between the memory reader entity 204 and the memory entity 202; (b) operating conditions within the molding system 100 (ex. temperature, pressure, vibration) and ability to withstand such operating conditions by the memory reader entity 204. Same considerations equally apply to the memory entity 202.

As an additional alternative, in some embodiments of the present invention, the pre-determined threshold can comprises a series of pre-determined thresholds, such as a first pre-determined threshold and a second pre-determined threshold, etc. Within these embodiments of the present invention, the method 200 can be modified as follows. The controller 180 compares a first indication of molding cycles (received as part of a first data element) to the first pre-determined threshold. Once it is determined that the number of molding cycles does not conform to the first pre-determined threshold, a first command signal comprising a first adjusted operational parameter is generated. The method 300 then loops back to step 320. The controller 180 then compares a second indication of the number of molding cycles (received as part of a second data element) to the second pre-determined threshold. Once it is determined, that the number of cycles does not conform to the second pre-determined threshold, a second command signal comprising a second adjusted operational parameter is generated. The second adjusted operational parameter can be a further adjustment to the first adjusted operational parameter or a further adjustment of a different operational parameter. The method 300 can be repeated with a third predetermined threshold and so on.

The description of the embodiments of the present inventions provides examples of the present invention, and these examples do not limit the scope of the present invention. It is to be expressly understood that the scope of the present invention is limited by the claims only. The concepts described above may be adapted for specific conditions and/or functions, and may be further extended to a variety of other applications that are within the scope of the present invention. Having thus described the embodiments of the present invention, it will be apparent that modifications and enhancements are possible without departing from the concepts as described. Therefore, what is to be protected by way of letters patent are limited only by the scope of the following claims:

Claims

1. A method (300) of operating a molding system (100), the molding system (100) including a molding system component (1 18) associated with a memory entity (202), the molding system further including a memory reader entity (204) configured to communicate with the memory entity (202), the method executable at a controller (180) of the molding system (100), the method (300) comprising: appreciating (320) from the memory reader entity (204) a data element associated with the memory entity (202), the data element being representative of a number of cycles undergone by the molding system component (1 18); responsive to the number of cycles not conforming to a pre-determined threshold, generating (330) a command signal, the command signal comprising at least one adjusted operational parameter for causing change in execution of at least one routine performed by the molding system (100), the change in execution of the at least one routine for preventing damage to at least a portion of the molding system (100).

2. The method (300) of claim 1, wherein said molding system component (1 18) is a wear component.

3. The method (300) of claim 1, wherein the molding system component (1 18) comprises at least one of: one or more mold cavities (1 18); a first mold half (1 14); a second mold half (1 16); one or more mold cores (120); one or more neck rings; one or more leader pins; one or more leader bushings; an End Of Arm Tool (126); auxiliary equipment associated with the molding system (100); one or more wedge bars; one or more seals used within the molding system (100); one or more bearings used within the molding system (100); one or more electronic components used within the molding system (100).

4. The method (300) of claim 1 , wherein the at least one routine comprises amount of clamp tonnage and wherein the at least one adjusted operational parameter is adjusted clamp tonnage parameter.

5. The method (300) of claim 1, wherein the at least one routine comprises injection pressure and wherein the at least one adjusted operational parameter is adjusted injection pressure.

6. The method (300) of claim 1, wherein the at least one routine comprises hold pressure and wherein the at least one adjusted operational parameter is adjusted hold pressure.

7. The method (300) of claim 1, wherein the at least one routine comprises speed of a stroke cylinder and wherein the at least one adjusted operational parameter is adjusted speed of the stroke cylinder.

8. The method (300) of claim 1, further comprising comparing the number of cycles to the pre-determined threshold.

9. The method (300) of claim 1, further comprising conveying a message to an operator, the message for indicating that the molding system component (1 18) requires replacement.

10. The method (300) of claim 1, further comprising enabling an operator to order a replacement for the molding system component (1 18).

1 1. The method (300) of claim 10, wherein said enabling is executed in response of the replacement not being available in an inventory, and wherein the method further comprises determining if the replacement is available by querying an inventory sub-system.

12. The method (300) of claim 1, the data element being a first data element, the predetermined threshold being a first pre-determined threshold, the command signal being a first command signal, the at least one adjusted operational parameter being a first adjusted operational parameter; and wherein the method further comprises: appreciating (320) from the memory reader entity (204) a second data element associated with the memory entity (202), the second data element being representative of the number of cycles undergone by the molding system component (1 18); responsive to the number of cycles not conforming to a second pre-determined threshold, generating (330) a second command signal, the second command signal comprising a second adjusted operational parameter.

13. The method (300) of claim 12, wherein said second adjusted operational parameter is different from said first adjusted operational parameter.

14. The method (300) of claim 12, wherein said second adjusted operational parameter is a further adjustment to said first adjusted operational parameter.

15. A molding system (100) comprising: a molding system component (1 18); a memory entity (202) associated with the molding system component (1 18); a memory reader entity (204) configured to communicate with the memory entity (202); a controller (180) being operable to communicate with the memory reader entity (204) and to control at least one routine executed within the molding system (100); the controller (180) being further operable: to appreciate from the memory reader entity (204) a data element associated with the memory entity (202), the data element being representative of a number of cycles undergone by the molding system component (118); responsive to the number of cycles not conforming to a pre-determined threshold, to generate a command signal, the command signal comprising at least one adjusted operational parameter for causing change in execution of the at least one routine performed by the molding system (100), the change in execution of the at least one routine for preventing damage to at least a portion of the molding system (100).

16. The molding system (100) of claim 15, wherein said molding system component (1 18) is a wear component.

17. The molding system (100) of claim 15, wherein the molding system component (1 18) comprises at least one of: one or more mold cavities (1 18); a first mold half (1 14); a second mold half (1 16); one or more mold cores (120); one or more neck rings; one or more leader pins; one or more leader bushings; an End Of Arm Tool (126); auxiliary equipment associated with the molding system (100); one or more wedge bars; one or more seals used within the molding system (100); one or more bearings used within the molding system (100); one or more electronic components used within the molding system (100).

18. The molding system (100) of claim 15, wherein the at least one routine comprises amount of clamp tonnage and wherein the at least one adjusted operational parameter is adjusted clamp tonnage parameter.

19. The molding system (100) of claim 15, wherein the at least one routine comprises injection pressure and wherein the at least one adjusted operational parameter is adjusted injection pressure.

20. The molding system (100) of claim 15, wherein the at least one routine comprises hold pressure and wherein the at least one adjusted operational parameter is adjusted hold pressure.

21. The molding system (100) of claim 15, wherein the at least one routine comprises speed of a stroke cylinder and wherein the at least one adjusted operational parameter is adjusted speed of the stroke cylinder.

22. The molding system (100) of claim 15, wherein the controller (180) is further operable to convey a message to an operator, the message for indicating that the molding system component (1 18) requires replacement.

23. The molding system (100) of claim 15, wherein the controller (180) is further operable to enable an operator to order a replacement for the molding system component (1 18).

24. The molding system (100) of claim 23, wherein the controller (180) is further operable to enable the operator to order the replacement in response to the replacement not being available in an inventory, and wherein the controller ( 180) is further operable to determine if the replacement is available by querying an inventory sub-system.

25. The molding system (100) of claim 15, the data element being a first data element, the pre-determined threshold being a first pre-determined threshold, the command signal being a first command signal, the at least one adjusted operational parameter being a first adjusted operational parameter; and wherein the controller (180) is further operable: to appreciate from the memory reader entity (204) a second data element associated with the memory entity (202), the second data element being representative of the number of cycles undergone by the molding system component (1 18); responsive to the number of cycles not conforming to a second pre-determined threshold, to generate a second command signal, the second command signal comprising a second adjusted operational parameter.