WO2019198039A2 - Système intelligent intégré et procédé destinés à estimer l'épaisseur réelle de films extrudés - Google Patents

Système intelligent intégré et procédé destinés à estimer l'épaisseur réelle de films extrudés Download PDF

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Publication number
WO2019198039A2
WO2019198039A2 PCT/IB2019/053016 IB2019053016W WO2019198039A2 WO 2019198039 A2 WO2019198039 A2 WO 2019198039A2 IB 2019053016 W IB2019053016 W IB 2019053016W WO 2019198039 A2 WO2019198039 A2 WO 2019198039A2
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WO
WIPO (PCT)
Prior art keywords
thickness
film
plc controller
recipe
estimated actual
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PCT/IB2019/053016
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English (en)
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WO2019198039A3 (fr
Inventor
Siddharth LOHIA
Original Assignee
Lohia Corp Limited
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Publication date
Application filed by Lohia Corp Limited filed Critical Lohia Corp Limited
Publication of WO2019198039A2 publication Critical patent/WO2019198039A2/fr
Publication of WO2019198039A3 publication Critical patent/WO2019198039A3/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
    • 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
    • B29C48/07—Flat, e.g. panels
    • B29C48/08—Flat, e.g. panels flexible, e.g. films
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/09—Articles with cross-sections having partially or fully enclosed cavities, e.g. pipes or channels
    • B29C48/10—Articles with cross-sections having partially or fully enclosed cavities, e.g. pipes or channels flexible, e.g. blown foils
    • 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
    • B29C48/30—Extrusion nozzles or dies
    • B29C48/305—Extrusion nozzles or dies having a wide opening, e.g. for forming sheets
    • B29C48/31—Extrusion nozzles or dies having a wide opening, e.g. for forming sheets being adjustable, i.e. having adjustable exit sections
    • B29C48/313—Extrusion nozzles or dies having a wide opening, e.g. for forming sheets being adjustable, i.e. having adjustable exit sections by positioning the die lips
    • 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
    • B29C48/30—Extrusion nozzles or dies
    • B29C48/32—Extrusion nozzles or dies with annular openings, e.g. for forming tubular articles
    • B29C48/325—Extrusion nozzles or dies with annular openings, e.g. for forming tubular articles being adjustable, i.e. having adjustable exit sections
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/92—Measuring, controlling or regulating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C2948/00—Indexing scheme relating to extrusion moulding
    • B29C2948/92—Measuring, controlling or regulating
    • B29C2948/92009—Measured parameter
    • B29C2948/92114—Dimensions
    • B29C2948/92152—Thickness
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C2948/00—Indexing scheme relating to extrusion moulding
    • B29C2948/92—Measuring, controlling or regulating
    • B29C2948/92009—Measured parameter
    • B29C2948/92228—Content, e.g. percentage of humidity, volatiles, contaminants or degassing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C2948/00—Indexing scheme relating to extrusion moulding
    • B29C2948/92—Measuring, controlling or regulating
    • B29C2948/92504—Controlled parameter
    • B29C2948/92609—Dimensions
    • B29C2948/92647—Thickness
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
    • G01B15/00—Measuring arrangements characterised by the use of electromagnetic waves or particle radiation, e.g. by the use of microwaves, X-rays, gamma rays or electrons
    • G01B15/02—Measuring arrangements characterised by the use of electromagnetic waves or particle radiation, e.g. by the use of microwaves, X-rays, gamma rays or electrons for measuring thickness

Definitions

  • the present invention relates to a method and an apparatus or a system (thickness measurement system or apparatus) for accurately measuring thickness of extruded plastic films.
  • the invention relates to automatic allocation of a recipe- dependent calibration factor to the measured thickness and applying changes to the thickness measurement system settings to minimize deviation of actual thickness from the measured thickness. Further in particular, a gauging-system-dependent calibration factor may be applied.
  • a plastic extrusion machine is designed to produce endless flat plastic film/sheet or blown film of PP, HOPE, LLDPE or other blends of polyolefin. Due to the limitations of existing technology, the thickness of these continuous plastic films/sheets produced through extrusion machines has different thickness at different position and differs with time interval which may have caused due to the non-uniform melt flow across the die and which leads to non-uniform product. Ensuring that the variation between the actual and specified values of the thickness of a film/sheet manufactured on a high-speed extrusion process line is necessary to maximize uniform production. Moreover, changes to recipe compositions are also an essential part of the woven sack industry in order to increase profitability.
  • thickness of plastic film/sheet produced from extrusion machines is measured with various kind of scanning systems or other thickness measurement system available for dedicated purpose of measuring thickness of a film/sheet or blown film.
  • These systems use online contactless measurement methods which use a source (emitter of some signal) and a detector (receiver of the signal) and where the source and detector are kept at either side of the fed film/sheet.
  • the measurement through these scanning systems may not be the function of polymer, additive master batch or any other filler contents. Further, accuracy of such systems depend upon how much actual thickness varies from the measured thickness.
  • thickness of the fed film/sheet depends on the filler material used in recipe of the composition.
  • the thickness measurement systems are typically calibrated using one recipe.
  • the actual recipes depend on the requirements of the individual sheet manufacturer and could be different from the one used to calibrate a system. In these circumstances, the settings of the thickness measurement devices should be changed using a calibration factor to match the actual recipes. If the actual recipe matches the one used for initial calibration of a thickness measurement system, no resetting is necessary. However, whenever changes are made to the recipe composition of the fed film/sheet, the thickness measured with a single calibration factor, would not be the actual thickness.
  • Beta gauge X- ray gauge (diffraction or fluorescence), infrared gauge, capacitive measurement method etc.
  • Technologies using Beta gauge is one of the most popular, however, as it involves a radioactive substances like Beta isotope there are drawbacks associated with it related to regulatory approvals, radiation-related health and safety matters, and half-life considerations.
  • technologies that employ X-ray gauges, capacitive gauges, gamma back scatter gauge, or infrared gauges are not capable of sensing the change in recipe composition.
  • the patent US5418830A disclosed that measurement signal seems to be sensitive to the variation in density of air present in the gap between source and detector as well as beta and x-rays are very sensitive to material composition of the film/sheet which cannot be neglected.
  • the patent US 4088886 discloses a method to find the calibration factor for running sheet material film by using X-ray florescence analyzer which provides measure of each quantity of metal alloy.
  • X-ray florescence analyzer which provides measure of each quantity of metal alloy.
  • the analyzer is not suitable for tubular film like blown film where there is no place to measure the composition before the extrusion die.
  • the patent US 3988582 described the method of measuring the thickness using back scatter principle of a blown film where source and detectors are at outside of the blown film.
  • This method in which air under pressure is supplied to the interior of an elongate plastic bubble, is not accurate as air gap between source/detector head and the bubble changes because of varying air pressure inside the bubble. This variation in distance between sensor head and bubble causes an erroneous measurement of the film thickness. It is therefore evident that there is currently no technical solution on the market satisfactory for measuring the thickness of a relatively varying density of the plastic sheet without changing the calibration factor.
  • the present invention discloses a method and an apparatus or a system (thickness measurement system or apparatus) for accurately estimating thickness of extruded plastic films.
  • the invention discloses how to automatically allocate a recipe-dependent calibration factor to the measured thickness in order to arrive at an estimate of the film thickness. It also discloses how to apply a calibration factor based on the guaging (or scanning) technology to the measured thickness to further improve the accuracy of estimation. It further discloses how to adjust the settings of the film forming die, on the basis of the estimated thickness, so that the actual thickness of the extruded film is within the acceptable range of deviation from the required thickness. Further in particular, a gauging-system-dependent calibration factor may be applied. In order to do so, depending on the electric signals issued by the PLC Controller unit to the film forming die unit for settings of the die-lip bolt at required location may be adjusted depending on whether the estimated actual thickness is within the acceptable limits of deviation from the required thickness.
  • FIG. 1 shows schematic of the intelligent integrated system of invention
  • FIG. 1 A shows the block diagram of signal transfer used in the invention
  • Figure 2 shows the correlation between the measured thickness and actual thickness
  • Figure 2A shows the discrete points used for measurement of thickness
  • Figure 3 shows the typical curve from which calibration factor is determined
  • the present invention provides a method for continuously reducing measurement deviations in film thickness measurement for flat/circular/blown film/sheet and point- to-point annular deviations in film thickness measurement for tubular film.
  • the method detects change in the proportion of the filler or other essential components of the said film/sheet and uses a varying recipe calibration factor as per the changed recipe of the composition.
  • the invention discloses an integrated intelligent film thickness system and a method for continuous change in recipe calibration factor.
  • the recipe calibration factor is defined as the ratio of measured thickness (measured using the measuring system/technology and the associated software) to actual thickness of the extruded film (2B).
  • recipe gauge factor the terms of measured thickness (measured using the measuring system/technology and the associated software) to actual thickness of the extruded film (2B).
  • recipe correction factor the terms of recipe proportionality factor are used to describe it.
  • the recipe has been defined in terms of the essential or key ingredients of a composition.
  • a recipe may be defined simply in terms of the inorganic content and polymer content.
  • the recipe may be defined in terms of the polymers, additives, etc.
  • the essential ingredients of a recipe may be determined.
  • a comprehensive first database (4) of recipes and corresponding recipe calibration factors is created using any system of measuring the actual film thickness.
  • the first database (4) is created on the basis of measurement of the film thickness for films of a number of recipes in controlled environment.
  • the recipe calibration factors for a large number of recipes are already saved in a database (4).
  • the first database (4) is created after performing number of experiments and resulting data saved in the first database (4) for most of the recipe used in the industry.
  • the first database (4) is capable of being updated to store the new recipe and the corresponding recipe calibration factor.
  • the accuracy of the thickness measurement is dependent on the different technologies deployed by the gauging systems - e.g. beta rays, x-ray, gamma rays, capacitive or infrared rays. This is because of the technological limitations of specific systems and the specific algorithms deployed by them. This means that the measurements carried out by different gauging techniques may be different.
  • the present invention also accounts for these dependencies by applying a further factor, termed as a‘gauging system calibration factor’ to the recipe calibration factor to arrive at the‘final calibration factor’.
  • the gauging system calibration factor is determined by measuring the same fdm using different technologies and arriving at the ratio of the measured thickness with the actual thickness.
  • the gauging system calibration factor may be determined for sheet produced using any one recipe and holds true for sheets produced using any other recipe.
  • a closest match is found in the first database (4) for the components of the specified recipe. The match may be exact or it may be extrapolation between any two or more points of the first database (4).
  • a corresponding recipe calibration factor is then computed by extrapolating between corresponding recipe calibration factors in the first database
  • the film thickness measurement system generates calculation error while showing the thickness on the display screen like an MMI (Man Machine Interface - not shown) when the recipe (the percentage of polymer material or any other filler component) changes.
  • MMI Man Machine Interface
  • the machine operator needs to input new calibration value or recipe values on MMI of the thickness measurement/scanning system to change its computing algorithm, every time recipe composition is changed in the dosing and mixing unit.
  • the first database (4) stored in the PLC (Programmable Logic Computing/Controller) controller controls the selection of recipe calibration factor corresponding to different recipe.
  • Figure 1 shows the block diagram of the intelligent integrated film thickness measurement system of invention to measure the thickness of a film. It shows a dosing and mixing unit (1) which supplies raw material to the extruded film manufacturing unit or extrusion unit or simply the extruder (2).
  • the extruder (2) is capable of producing a flat or circular or blown type film through the film forming die (6).
  • the film (2B) that is formed by the film forming die (6) proceeds to a gauging system (3) (alternatively a gauging unit or a gauging device) that scans the film (2B) and collects data regarding the film’s thickness at discrete points (3 A) across the width of the film (2B).
  • the gauging system (3) is capable of using any conventional technologies of thickness measurement such as beta rays, x-ray, gamma rays, capacitive or infrared rays.
  • the film forming die may be linear type (which produces a flat sheet with edges) or annular type (which produces a tubular film).
  • the discrete points (3 A) may be spread across the entire width of the flat film or throughout the perimeter of the tubular film.
  • the film forming die has die bolts; each die bolt corresponding to at least one discrete point (3A).
  • the scanning system (3) measures thickness at least at discrete points (3 A). It may collect data at other points on the film (2B).
  • the first database (4) itself is stored within a PLC Controller unit (5).
  • the recipe composition of the film that is being scanned is compared with the recipes inside the first database and on the basis of which a calibration factor suitable for the current recipe is selected from the database by the PLC Controller unit (5).
  • a correction is applied by the PLC Controller Unit (5) to the measured thickness at discrete points (3 A) to arrive at the best estimate of the actual thickness at discrete points (3 A) of the film.
  • the measured thickness is multiplied by the recipe calibration factor to arrive at the estimated actual thickness at the discrete points (3 A) of the extruded film (2B).
  • the thickness data is collected by the scanning unit (3) at discrete points (3 A) across the width of the fdm (2B).
  • the fdm forming die has a number of die-bolts spread across the width of the film.
  • a signal is sent by the PLC Controller unit (5) to the film forming die (6) so as to adjust the settings of die-lip-bolt unit (not shown) to minimize the deviation at a location corresponding to a particular one or more discrete point (3 A) along the width of the film (2B).
  • This process of adjustment of the die-lip bolts is automated in the case of automated gauging film forming die systems and manual in the case of manual automated gauging film forming die systems.
  • the adjustment process is also iterative and carried out until the deviation at all discrete points (3 A) is within the acceptable limit.
  • the estimated overall thickness of the film (2B) itself is determined by averaging the estimated thickness measured at discrete points (3A). Any averaging technique such as statistical method/technique of averaging, including computing simple arithmetic average, may be used. It is important to note that there’s a time lag between the time when the raw material is fed to the mixing and dosing unit and when the film comes to the scanning unit of the gauging system.
  • a second database (4A) of gauging systems and corresponding gauging system calibration factors is also maintained within the PLC Controller Unit (5).
  • the gauging system calibration factor corresponding to the actual system of thickness measurement used is applied to the recipe calibration factor to arrive at the final calibration factor which is applied to the measured thickness to arrive at the estimated actual thickness.
  • the recipe calibration factor is multiplied by the gauging system calibration factor to arrive at the final calibration factor.
  • the final calibration factor is the same as the recipe calibration factor.
  • the PLC Controller (5) is notified by the mixing and dosing unit (1) of the time of feeding of new recipe to the dosing and mixing and unit (1) and the details of the recipe composition itself. Time of arrival of the film manufactured according to the new recipe is calculated on the basis of the production speed of the extruder.
  • the PLC Controller (5) resets the recipe calibration factor at a time to coincide with the arrival of the film (2B) of the new recipe at the gauging unit and uses it to calculate estimated actual film thickness.
  • the detail of recipe from dosing and mixing unit (1) is communicated to PLC controller (5) and compared with the first database (4) which is stored in PLC controller (5) itself.
  • the PLC controller (5) provides a representation of an integrated intelligent film thickness measurement system (S) which is a control system which links dosing and mixing unit (1) and gauging system (3) with the first database (4).
  • the integrated intelligent film thickness measurement system (S) automatically updates the changes in dosing unit (1) in suitable time interval to the film thickness scanning system.
  • the PLC controller (5) is a main controller of the complete extrusion machine and responsible for many functions apart from the ones such as running the extruder, reading the temperature and pressure of different components of an extrusion machine. It is a master controller responsible for any logic control in the complete system.
  • the second database (4A) is capable of accepting data for new thickness measuring technologies as and when they are available.
  • the recipes change a number of times during the manufacture of a film depending on the customer requirement or specific purpose for which the film is manufactured. Let us assume that a film requires A, B, and C as raw materials supplied to the dosing and mixing unit in proportions x%, y%, and z % respectively. At the start of the manufacturing process, this information is fed to the system.
  • the PLC Controller (5) calculates/allocates a calibration factor and corrected the measured thickness value to actual thickness of film.
  • the invention provides the capability of adjusting required location die-lip bolt settings depending on the changes to recipe and the resultant deviation of the estimated actual thickness from the required or specified thickness.
  • the method of invention uses an integrated intelligent thickness measurement system (S) incorporating an extrusion machine and controls the filler composition detail from the separate/common man-machine interface (MMI) of dosing and mixing unit (1). Further the method takes cognizance of the change in recipe material, determine the need to recalculate and reset the calibration factor at the time when the film manufactured arrives at the gauging system. The method also takes cognizance of the technology deployed at the gauging unit and further modifies the calibration factor to arrive at a final calibration factor. This integration brings the complete system on a common controlling platform to reduce the manual errors in compensating for recipe (through the use of the recipe calibration factor) and measurement technology changes (through the use of the gauging calibration factor).
  • S thickness measurement system
  • MMI separate/common man-machine interface
  • Figure 2 shows a block diagram that represents that measured thickness from gauge may not be the actual thickness of the manufactured film (2B).
  • the method of invention allows making an estimate of the actual thickness on the basis of the measured thickness by applying a calibration factor or a final calibration factor.
  • the estimated actual thickness of a manufactured film as calculated using the method of invention is far superior than the thickness estimated using conventional methods.
  • Figure 3 represents the behavior of calibration factor with respect to different recipe contents.
  • the amount of change in calibration factor depends upon filler/ content material of the extruded film and type of thickness gauge used in the system.
  • an integrated intelligent film thickness measurement system and a method for continuous change in calibration factor is developed.
  • This integrated intelligent system is a combination of dosing and mixing unit, online thickness measurement system and database. Thickness measurement system can be linked with dosing and mixing unit and complete extrusion machine through any conventional methods of communication.
  • the integrated intelligent film thickness measurement system ensures real time updating to the scanning system (3) considering the delay of material movement from the dosing and mixing unit to the scanning system. This minimizes any kind of computational error in the scanning system (3) due to the material flow delay. Material flow delay can vary with the line speed of the machine. The system will calculate delay of material flow and then intelligently assign the recipe calibration factor to the gauging system (3).
  • the dosing and mixing unit (1) is designed such that it keeps record of each component of material which is selected through its MMI and transfers new recipe parameters to the scanning system on detection of every change.
  • the dosing and mixing unit can communicate updated parameters to film thickness measurement system on redundant digital or analog bus in case of integrated and distributed systems, which ensures delivery of relevant parameters between units.
  • a method for online thickness measurement of extruded films comprises the following steps:
  • an intelligent integrated film thickness measurement system comprising a dosing and mixing unit (1), an extruder unit (2), a scanning system (3), a film forming die unit (6), a first database (4) of recipe calibration factors, an optional second database (4A) of gauging system calibration factors, a PLC Controller unit (5), wherein said PLC Controller unit is capable of controlling operations of other units of the system (S);
  • the PLC controller (5) computing the deviation between the required film thickness and the estimated actual thickness and checking whether the deviation is greater than a predetermined acceptable limit, and making a record of the corresponding discrete points (3 A);
  • the PLC controller (5) computing and sending electric signals to film forming die (6) so that adjustment may be made to the setting of the die-lip bolt corresponding to the recorded discrete points (3 A) to bring said deviation within said predetermined acceptable limit; j. Repeating steps f and h until the deviation is greater than or equal to the predetermined acceptable limit.
  • an intelligent integrated film thickness measurement system (S) or an apparatus to carry out the method disclosed herein.
  • the system or the apparatus comprises:
  • a dosing and mixing unit (1) capable of receiving raw material and mixing it and sending it down to an extruder unit (2).
  • the dosing and mixing unit is also connected to a PLC controller (5) to which data regarding the composition of ingredients of the film to be produced are fed.
  • the extruder unit (2) being capable of receiving the raw material from the dosing and mixing unit (1) and manufacturing a film (2B) through a film forming die (6).
  • the gauging unit (3) for scanning the film (2B) for measurement of its thickness is a part of the gauging unit (3) for scanning the film (2B) for measurement of its thickness.
  • the PLC controller (5) controls the manufacturing process and also houses a first database (4) of recipes and corresponding calibration factors. It also optionally contains a second database (4A) of gauging technologies and corresponding gauging calibration factors.
  • the PLC controller (5) is capable of receiving data from and sending it, in the form of electric signals, to other components of the apparatus such as the mixing and dosing unit (1), and the gauging unit (3).
  • PLC controller (5) makes the necessary computations such as estimated actual thickness computation and computation of deviation of the estimated actual thickness from the required thickness of the film (2B).
  • the PLC controller is also optionally capable of receiving instructions/data from and sending it to film forming die (6) to adjust the die-lip bolt settings.
  • the gauging unit (3) scans the film (2B) and obtains thickness measurements at discrete points (3A) and sends it back to the PLC controller (5) for estimated actual thickness computation at discrete points (3 A).
  • the main advantage of the inventive system is to have real time seamless updating of changes in process/receipe to the thickness measurement and control system without any human interference, ensuring uniform desired film product.
  • An extruded film of actual thickness of 80 microns, and whose inorganic content was around 40% and polymer content around 60% was measured using conventional method and conventional thickness measuring system.
  • the measuring system had a fixed single gauging factor of 1.5.
  • the measured thickness was therefore 115 microns and the resultant difference/error between actual film thickness and measured film thickness was around 44%.
  • the thickness of the same film was assessed using the system of invention operating using an X-ray gauging method.
  • a recipe gauge factor of 0.8 was assigned on the basis of the inorganic content and the rest of the recipe of the raw material.
  • the estimated actual thickness calculated according to the method of invention was therefore 78 micron. This is around 2.5% deviation from the actual thickness.
  • An integrated intelligent system (S) for estimating actual thickness of extruded films characterized in that said system is capable of measuring thickness of said extruded film (2B) and modifying it by a final calibration factor to compute estimated actual thickness at discrete points (3A) of said film.
  • an extruder unit (2) which receives the raw material from said dosing and mixing unit (1) and manufactures an extruded fdm (2B) through a film forming die (6); a gauging unit (3) for scanning said extruded film (2B) for thickness measurement, wherein said gauging unit scans the film (2B) and obtains measurement of actual thickness at predetermined discrete points (3 A) across the width of said film (2B) and sends said obtained measurements back to said PLC controller (5) for estimated actual thickness computation; wherein said PLC controller (5) controls manufacturing process of said extruded film (2B) and also houses a first database (4) of raw material recipes and corresponding recipe calibration factors, and wherein said PLC controller (5) is capable of receiving data from and sending data to other components of the system such as said dosing and mixing unit (1), said extruder unit (2), and said gauging unit (3); further wherein said PLC controller (5) being capable of determining a recipe calibration factor and making the necessary computations such as estimated actual thickness computation and computation of deviation of
  • said PLC controller (5) optionally stores a second database (4A) of gauging calibration factors corresponding to available gauging technologies.
  • said estimated actual thickness computation consists of multiplying the actual measured thickness of said film (2B) by said recipe calibration factor, said estimated actual thickness computation being carried out at discrete points (3A) where estimated actual film thickness has been measured.
  • said estimated actual thickness computation consists of multiplying the actual measured thickness of said film (2B) by said recipe calibration factor and by said gauging calibration factor, said estimated actual thickness computation being carried out at discrete points (3 A) where estimated actual film thickness has been measured.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Extrusion Moulding Of Plastics Or The Like (AREA)

Abstract

La présente invention concerne un système et un procédé destinés à estimer de façon précise l'épaisseur de films plastiques extrudés. En particulier, l'invention comprend l'étape consistant à attribuer automatiquement un facteur d'étalonnage dépendant de la recette et un facteur d'étalonnage dépendant du système de balayage, à l'épaisseur mesurée, pour parvenir à une estimation précise. L'invention comprend également une étape consistant à effectuer des modifications des réglages de la filière de formation de film pour réduire l'écart de l'épaisseur réelle à partir de l'épaisseur requise du film. L'invention traite le problème posé par les systèmes d'extrusion classiques dans lesquels les films sont souvent d'une épaisseur non uniforme inacceptable. L'invention comprend une unité de commande PLC (5) qui est capable de recevoir à partir d'autres composants et d'envoyer à ces autres composants, des données sous la forme de signaux électriques. L'unitér PLC (5) effectue des calculs du calcul de l'épaisseur réelle estimée et du calcul de l'écart de cette épaisseur à partir de l'épaisseur requise. L'unité de commande PLC est, le cas échéant, également capable de recevoir à partir de la filière de formation de film (6) et d'envoyer à cette filière, des instructions/données, pour ajuster les réglages de boulon de lèvre de filière.
PCT/IB2019/053016 2018-04-14 2019-04-12 Système intelligent intégré et procédé destinés à estimer l'épaisseur réelle de films extrudés WO2019198039A2 (fr)

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IN201711044970 2018-04-14
IN201711044970 2018-04-14

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WO2019198039A2 true WO2019198039A2 (fr) 2019-10-17
WO2019198039A3 WO2019198039A3 (fr) 2019-11-14

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Citations (3)

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Publication number Priority date Publication date Assignee Title
US3988582A (en) 1975-08-28 1976-10-26 Nucleonic Data Systems, Inc. Blown film thickness gauge
US4088886A (en) 1975-09-22 1978-05-09 Nucleonic Data Systems Radiation thickness gauge for sheet material
US5418830A (en) 1992-05-15 1995-05-23 Scan-Tech S.A. Radiometric thickness measurement gage

Family Cites Families (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4803715A (en) * 1986-10-10 1989-02-07 Process Automation Business, Inc. Thickness measurement with automatic correction for changes in composition
DE10345754A1 (de) * 2003-09-23 2005-04-21 Mesacon Messelektronik Gmbh Dr Vorrichtung und Verfahren zur Bestimmung der Dicke bewegter metallischer, bandförmiger Werkstoffe
EP1780500A1 (fr) * 2005-10-28 2007-05-02 Hch. Kündig & Cie. AG Procédé destiné à la mesure de l'épaisseur de feuilles à plusieurs couches
EP2026032A1 (fr) * 2007-08-16 2009-02-18 Hch. Kündig & Cie. AG Mesure de l'épaisseur d'une monocouche d'un film multicouche
JP6623737B2 (ja) * 2015-12-15 2019-12-25 コニカミノルタ株式会社 光学フィルムの製造方法および製造装置
JP6538642B2 (ja) * 2016-03-02 2019-07-03 富士フイルム株式会社 製膜装置及び方法
EP3448645B1 (fr) * 2016-04-29 2023-08-09 Aplix Appareil de moulage pour la formation d'un dispositif de retenue
FR3052698B1 (fr) * 2016-06-15 2019-08-09 Centre National De La Recherche Scientifique Procede et appareil pour la fabrication d'un systeme mecatronique par impression tridimensionnelle

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3988582A (en) 1975-08-28 1976-10-26 Nucleonic Data Systems, Inc. Blown film thickness gauge
US4088886A (en) 1975-09-22 1978-05-09 Nucleonic Data Systems Radiation thickness gauge for sheet material
US5418830A (en) 1992-05-15 1995-05-23 Scan-Tech S.A. Radiometric thickness measurement gage

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TWI707762B (zh) 2020-10-21
TW202003201A (zh) 2020-01-16
WO2019198039A3 (fr) 2019-11-14

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