Electro - actuator driven for injection molding flow control

Abstract

An injection molding apparatus (1) comprising: an actuator (14, 940, 941, 942) including a rotor (940r, 941r, 942r) that is controllably rotatable by electricity, the actuator (14, 940, 941, 942) being interconnected with a controller (16) that generates a drive signal (DC); an electric drive device (940d, 941d, 942d) including an interface that receives the drive signal (DC) and controllably distributes electrical energy or power to a driver (940dr, 941dr, 942dr) that drives the rotor (940r, 941r, 942r) in a controllably variable amount in accordance with the drive signal (DC); valve pins (1040, 1041, 1042) having an axis (X) and a control surface (43, 45, 102m) that is drivable upstream and downstream through a downstream feed channel (17, 19, 160, 940c, 941c, 942c) having complementary surfaces (47, 103s) adapted to engage the control surface (43, 45, 102m) upstream and remote from the gate.

Description

BACKGROUND OF THE INVENTION

[0001] As disclosed in U.S. Patent Nos. 6,294,122, 6,464,909, 7,597,828, 7,029,268, and 7,234,929, injection molding systems have been developed for controlling fluid flow using an electric actuator and for controlling fluid flow from upstream of a gate to a mold cavity, the disclosures of all of the above patents being incorporated herein by reference as if fully set forth herein in their entirety. SUMMARY OF THE INVENTION

[0002] According to the present invention, there is provided an injection molding apparatus (1) comprising: an injection molding machine (500), a manifold (15) that receives an injection fluid material (13) from the injection molding machine (500) under pressure, a mold (25, 27, 300) having cavities (5, 30), and at least one valve, the valve comprising:

[0003] An actuator (14, 940, 941, 942) including a rotor (940r, 941r, 942r) rotatable by electric control, the actuator (14, 940, 941, 942) being interconnected to a controller (16) that generates a digital signal (DC) received by a drive device (940d, 941d, 942d) mounted to or housed within an actuator housing (940h, 941h, 942h) that houses the rotor (940r, 941r, 942r), the drive device utilizing the drive signal (DC) to control the rotational movement of the rotor (940r, 941r, 942r).

[0004] A valve pin (1040, 1041, 1042) includes a shaft having an axis (X) and a protrusion (102) disposed at a selected position along the axis of the shaft, the valve pin being interconnected at an upstream end to the rotor in an arrangement in which the valve pin is controllably drivable upstream and downstream along a linear travel path (XX) through a downstream feed channel (17, 19, 160, 940c, 941c, 942c) that directs the injection material to and through a gate leading to the cavity of the mold.

[0005] A protrusion (102) having a control surface (45, 102m) and a downstream feed channel having a complementary surface (47, 103s), the complementary surface (47, 103s) being adapted to controllably vary the flow rate in accordance with a controlled axial positioning of the control surface (45, 102m) of the protrusion (102) relative to the complementary surface (47, 103s) of the downstream feed channel (17, 19, 160, 940c, 941c, 942c).

[0006] An actuator generally includes a driver (940dr, 941dr, 942dr) that receives electrical energy or power from a drive device (940d, 941d, 942d), and the drive device (940d, 941d, 942d) includes an interface that receives and controllably distributes electrical energy or power to the driver (940dr, 941dr, 942dr) in a controllably variable amount during the course of an injection cycle.

[0007] The brake housing may be adapted to accommodate an electric drive (940d, 941d, 942d), a rotor (940r, 941r, 942r), and a driver (940dr, 941dr, 942dr) and support the rotor (940r, 941r, 942r) for rotatable driving, wherein the actuator housing (940h, 941h, 942h) is mounted adjacent to or in alignment with a heated manifold (40) such that one or the other or both of the housing (940h, 941h, 942h) and the electric drive (940d, 941d, 942d) are in substantially thermal communication with the heated manifold (40).

[0008] In another aspect of the present invention, there is provided an apparatus (1) including: an injection molding machine (500), a manifold (15) that receives an injection fluid material (13) from the injection molding machine (500) under pressure, and a mold (25, 27, 300) having a cavity (5, 30) and at least one valve, the valve including:

[0009] The actuator (14, 940, 941, 942) includes a rotor (940r, 941r, 942r) that is controllably rotatable by electricity, and the actuator (14, 940, 941, 942) is interconnected with a controller (16) that generates a control signal.

[0010] A drive device (940d, 941d, 942d) interconnected with the controller (16), the drive device including an interface that receives electrical energy or power according to the control signal and controllably distributes it in a controllably variable amount to a driver (940dr, 941dr, 942dr) of the rotor (940r, 941r, 942r) during the course of an injection cycle,

[0011] The valve pins (1040, 1041, 1042) include a shaft having an axis (X) and a protrusion (102) disposed at a selected position along the axis of the shaft, and the valve pins are interconnected to the rotor at the upstream end in an arrangement such that the valve pins can be controllably driven upstream and downstream along a linear travel path (XX) through a downstream feed channel (17, 19, 160, 940c, 941c, 942c) that directs the injection material to and through a gate leading to the cavity of the mold.

[0012] A projection (102) having a control surface (45, 102m) and a downstream feed channel having a complementary surface (47, 103s), the complementary surface (47, 103s) being adapted to controllably vary the flow rate in accordance with the controlled axial positioning of the control surface (45, 102m) of the projection (102) relative to the complementary surface (47, 103s) of the downstream feed channel (17, 19, 160, 940c, 941c, 942c).

[0013] In such a device, a controller (16) can generate a digital control signal (DC), and a driver is adapted to receive and utilize the digital control signal (DC) to control the rotational movement of a rotor (940r, 941r, 942r).

[0014] The drive means is (940d, 941d, 942d) and is typically mounted to or housed within an actuator housing (940h, 941h, 942h) that houses the rotor (940r, 941r, 942r).

[0015] The actuator housing is typically adapted to house the drive means (940d, 941d, 942d), the rotor (940r, 941r, 942r) and the driver (940dr, 941dr, 942dr) and to support the rotor (940r, 941r, 942r) for rotatable driving, wherein the actuator housing (940h, 941h, 942h) is mounted close to or in alignment with a heated manifold (40) such that one or the other or both of the housing (940h, 941h, 942h) and the electric drive means (940d, 941d, 942d) are in substantial thermal communication with the heated manifold (40).

[0016] In another aspect of the present invention, there is provided an injection molding apparatus (1) comprising: an injection molding machine (500), a manifold (15) receiving an injection fluid material (13) from the injection molding machine (500) under pressure, and a mold (25, 27, 300) having a cavity (5, 30) and at least one valve, the valve comprising:

[0017] The actuator (14, 940, 941, 942) includes a rotor (940r, 941r, 942r) that is controllably rotatable by electricity, the actuator (14, 940, 941, 942) being interconnected with a controller (16) that generates a control signal that distributes electrical energy or power to a driver (940dr, 941dr, 942dr) of the rotor (940r, 941r, 942r) in a controllably variable amount during an injection cycle in accordance with the control signal.

[0018] The valve pins (1040, 1041, 1042) include a shaft having an axis (X) and a projection (102) disposed at a selected position along the axis of the shaft. The valve pins are interconnected to the rotor at the upstream end in an arrangement where the valve pins can be controllably driven upstream and downstream along a linear travel path (XX) through downstream feed channels (17, 19, 160, 940c, 941c, 942c), and the downstream feed channels (17, 19, 160, 940c, 941c, 942c) direct the injection material to and through a gate leading to a cavity of the mold.

[0019] The projection (102) having a control surface (45, 102m) and the downstream feed channels having complementary surfaces (47, 103s) are adapted to (a) controllably vary the flow rate according to the controlled axial positioning of the control surface (45, 102m) of the projection (102) relative to the complementary surfaces (47, 103s) of the downstream feed channels (17, 19, 160, 940c, 941c, 942c), and (b) enable the reaction force of the injected fluid material (13) on the valve pins (1040, 1041, 1042) to use a motor having a maximum power or energy output of approximately constant value.

[0020] Such a device typically further includes drive means (940d, 941d, 942d) interconnected to a controller (16), and the drive means includes an interface that receives electrical energy or power according to a control signal generated by the controller (16) during the injection cycle and controllably distributes the electrical energy or power in a controllably variable amount to the drivers (940dr, 941dr, 942dr) of the rotor (940r, 941r, 942r).

[0021] In another aspect of the present invention, there is provided an injection molding apparatus (1) comprising: an injection molding machine (500); a manifold (15) which receives injection material (18) under pressure from the injection molding machine (500); a mold (25, 27, 300) having a cavity (5, 30) and at least one valve, the valve comprising: an actuator (14, 940, 941, 942) including a rotor (940r, 941r, 942r) capable of being controllably rotated by electricity, the actuator (14, 940, 941, 942) being interconnected with a controller (16) that generates a drive signal (DC); an electric drive device (940d, 941d, 942d) including an interface which receives the drive signal (DC) and controllably distributes electrical energy or power in a controllably variable amount to a driver (940dr, 941dr, 942dr) that drives the rotor (940r, 941r, 942r) according to the drive signal (DC); a valve pin (1040, 1041, 1042) including a shaft having an axis (X) and a control surface (43, 45, 102m) disposed at a selected position along the axis (X) of the shaft, the valve pin being interconnected with the rotor at an upstream end in one arrangement, wherein the valve pin is controllably drivable upstream and downstream along a linear travel path (XX) through a downstream feed channel (17, 19, 160, 940c, 941c, 942c) which directs the injection material to and through a gate (7, 9, 32, 34, 36) leading to the cavity of the mold, the downstream feed channel having complementary surfaces (47, 103s) adapted to engage the control surface (43, 45, 102m) to controllably vary the rate or velocity of flow according to the controlled axial positioning of the control surface (43, 45, 102m) relative to the complementary surfaces (47, 103s) of the downstream feed channel (17, 19, 160, 940c, 941c, 942c).

[0022] The complementary surfaces (47, 103s) are preferably disposed upstream of and remote from the gate (7, 9, 32, 34, 36).

[0023] The electric drive device (940d, 941d, 942d) generally receives electrical energy or power from a power source (PS) and controllably distributes the received electrical energy or power in a controllably variable amount to the driver (940dr, 941dr, 942dr) during the course of an injection cycle.

[0024] An electric drive device (940d, 941d, 942d) generally includes a pulse width modulator (PWM) that converts received electrical energy or power into a sinusoidal voltage waveform, each sinusoidal voltage waveform being adapted to drive a corresponding phase coil of an actuator driver (940dr, 941dr, 942dr).

[0025] The pulse width modulator (PWM) generally includes an inverter or a comparator.

[0026] The pulse width modulator (PWM) may include a three-phase inverter that converts electrical energy or power received from an interface into three sinusoidal voltage waveforms, each of the three sinusoidal voltage waveforms being adapted to drive a corresponding one of three phase coils of an actuator driver.

[0027] The electrical energy or power received at or by the pulse width modulator (PWM) generally includes a DC bus voltage.

[0028] The interface (940d, 941d, 942d) of the electric drive device may be adapted to receive one or more control signals from a controller (16) of an injection molding device (10) and convert electrical energy or power received from a power source (PS) into a sinusoidal waveform based on the one or more control signals.

[0029] The interface generally includes a pulse width modulator (PWM) that converts electrical energy or power received from a power source into a sinusoidal waveform based on one or more control signals.

[0030] One or more control signals received by the interface may include control information that causes the pulse width modulator (PWM) to convert the received electrical energy or power into a sinusoidal waveform adapted to drive a corresponding phase coil of an actuator driver to adjust one or more of the position, speed, or torque of an actuator rotor (940r, 941r, 942r).

[0031] One or more control signals may include an analog electrical signal received from a controller (16) at the electric drive.

[0032] The electric drive device (940d, 941d, 942d) generally includes one or the other or both of a digital signal receiving (16r) and sending (16s) device, wherein: the digital signal receiving and sending device is adapted to receive (16r) and send (16s) digital signals between the electric drive device (940d, 941d, 942d) and a controller (16) of an injection molding device (10); and wherein the digital signal includes one or more control signals, and one or more control signals are digital control signals received from the controller.

[0033] The digital control signal may include one or more of a differential position command, a differential current command, and a differential speed command.

[0034] The digital signal receiving and transmitting device (16r, 16s) is generally adapted to receive a digital signal from the actuator, where the digital signal received from the actuator includes one or more feedback signals corresponding to the operation of one or more of the actuator and the actuator rotor.

[0035] The pulse width modulator (PWM) generally converts electrical energy or power received from the interface into a sine wave form, which is adapted to drive the corresponding phase coils of the actuator driver at least partially based on one or more feedback signals. One or more feedback signals received from the actuator may include one or more of an incremental feedback signal and an absolute feedback signal.

[0036] The actuator generally has a housing (940h, 941h, 942h) that houses a rotor (940r, 941r, 942r) and a driver (940dr, 941dr, 942dr), and the housing is adapted to support the rotor (940r, 941r, 942r), and the electric drive device (940d, 941d, 942d) is housed within the housing (940h, 941h, 942h) or is housed by the housing (940h, 941h, 942h), or is mounted on the housing (940h, 941h, 942h) or is mounted to the housing (940h, 941h, 942h), where the housing (940h, 941h, 942h) is mounted close to or in alignment with the heated manifold (40) such that one or the other or both of the housing (940h, 941h, 942h) and the electric driver (940d, 941d, 942d) are in substantially thermal communication or contact with the heated manifold (40).

[0037] The housing (940h, 941h, 942h) may be mounted on or to the splint (80) in an arrangement such that one or the other or both of the housing (940h, 941h, 942h) and the electric drive device (940d, 941d, 942d) are in substantially heat communication or thermal communication with the heated manifold (40).

[0038] The housing (940h, 941h, 942h) of the actuator can be interconnected with a linear stroke converter (940l, 941l, 942l) in an arrangement in which the valve pins (1040, 1041, 1042) are adapted to be driven along a linear axis (X) non - coaxial with respect to the drive shaft (y). The linear stroke converter (940l, 941l, 942l) is mounted on the heated manifold (40) or mounted to the heated manifold (40) or arranged to be in thermally conductive communication with the heated manifold (40).

[0039] The linear stroke converter (940l, 941l, 942l) is mounted on one or the other or both of the heated manifold (40) or the clamping plate (80) or mounted to one or the other or both of the heated manifold (40) or the clamping plate (80).

[0040] The linear stroke converter generally includes a converter housing (940lh) mounted in direct or indirect thermally conductive contact with the heated manifold (40), and the housings (940h, 941h, 942h) are connected to the converter housing (940lh) in a manner thermally conductive therewith.

[0041] The linear stroke converter generally includes a converter housing (940lh) that is mounted on or mounted to a mounting member made of a metallic material, and the mounting member is mounted in direct metal - to - metal contact or communication with the heated manifold (40).

[0042] The valve pins (1040, 1041, 1042) can have an upstream end (1041ue) coupled to the actuator, a downstream end (1041de) that closes the gate when the valve pin moves downstream to the gate - closed position, and control surfaces (43, 45, 102m) are provided at a selected axial position intermediate the upstream end (1041ue) and the downstream end (1041de). The control surfaces (43, 45, 102m) are adapted to interact with complementary surfaces (103s) to reduce the flow rate of the material when the valve pin moves upstream through a selected stroke path (CP), and to increase the material flow rate when the valve pin moves downstream through the selected travel path (CP).

[0043] Such a device generally includes sensors (PS0, PS1, PS1a, PS2, PS2a) for sensing the pressure of the injection material, and the sensors (PS0, PS1, PS1a, PS2, PS2a) send signals representative of the sensed pressure to a controller (16). The controller includes instructions for comparing the sensed pressure with a target pressure and adjusting the axial position of the valve pin so that the material pressure is adjusted to track the target pressure.

[0044] The sensor is preferably adapted to sense the injection material pressure at a position downstream of the control surface of the valve pin.

[0045] An actuator generally includes a driver (940d, 941d, 942d) that receives electrical energy or power from a drive device (940d, 941d, 942d), and the drive device (940d, 941d, 942d) includes an interface that receives and controllably distributes electrical energy or power to the driver (940d, 941d, 942d) in a controllably variable amount during the course of an injection cycle.

[0046] The complementary surfaces (47, 103s) and the control surfaces (43, 45, 102m) generally have a maximum diameter or radial dimension of about 12 mm.

[0047] The complementary surfaces (47, 103s) and the control surfaces (43, 45, 102m) may have a maximum diameter or radial dimension of about 10 mm.

[0048] In another aspect of the present invention, there is provided an injection molding apparatus (1) comprising: an injection molding machine (500); a manifold (15) that receives injection material (13) from the injection molding machine (500) under pressure; a mold (25, 27, 300) having a cavity (5, 30) and at least one valve, the valve comprising: an actuator (14, 940, 941, 942) including a rotor (940r, 941r, 942r) that is controllably rotatable by electricity, the actuator (14, 940, 941, 942) being interconnected with a controller (16) that generates a drive signal (DC); an electric drive device (940d, 941d, 942d) including an interface that receives the drive signal (DC) and controllably distributes electrical energy or power to a driver (940r, 941r, 942dr) that drives the rotor (940r, 941r, 942r) in a controllably variable amount in accordance with the drive signal (DC); a valve pin (1040, 1041, 1042) including a shaft having an axis (X), the valve pin being interconnected with the rotor in an arrangement at an upstream end (1041ue), wherein the valve pin can be controllably driven upstream and downstream by the actuator (14, 940, 941, 942) along a linear travel path (XX) through a downstream feed channel (940c, 941c, 942c), the valve pin and the downstream feed channel being adapted to engage with each other to change the rate or velocity of the flow of the injection material to and through a gate (7, 9, 32, 34, 36) leading to the cavity of the mold; a sensor (PS0, PS1, PS1a, PS2, PS2a) that senses the pressure of the injection material in a channel (17, 19, 940c, 941c, 942c, 5011) upstream of the gate (7, 9, 32, 34, 36); a controller (16) including a program that receives a signal indicating the sensed pressure from the sensor and generates an instruction based on the received signal, the signal being sent to the actuator (14, 940, 941, 942) through the electric drive device (940d, 941d, 942d); the instruction controlling the engagement of the valve pin and the downstream feed channel to control the rate or velocity of the flow of the injection material during an injection cycle.

[0049] In such an apparatus, the downstream feed channel preferably has complementary surfaces (47, 103s) that are adapted to engage with control surfaces (43, 45, 102m) such that the upstream force of the reaction applied to the valve pin (1040, 1041, 1042) is minimized.

[0050] In such an apparatus, the downstream feed channel generally has complementary surfaces (47, 103s) that are adapted to engage with control surfaces (43, 45, 102m) at a position upstream of and remote from the gate (32, 34, 36).

[0051] In such a device, the electric drive means (940d, 941d, 942d) may comprise either one or the other or both of digital signal receiving (16r) and sending (16s) means, wherein: the digital signal receiving and sending means are adapted to receive (16r) and send (16s) digital signals between the electric drive means (940d, 941d, 942d) and the controller (16) of the injection moulding device (10); and wherein the digital signal comprises one or more control signals, wherein the one or more control signals are digital control signals received from the controller (16).

[0052] Such a device may include position sensors (POS, POS0, POS1, POS2) which send position signals (POS0s, POS1s, POS2s) indicating the position of the valve pins (1040, 1041, 1042) to the controller (16), the program including instructions which utilize the position signals to indicate that the actuator (14, 940, 941, 942) moves the valve pins (1040, 1041, 1042) to one or more predetermined positions during the course of the injection cycle.

[0053] In such a device, the actuator (940, 941, 942) and the controller (16) may be adapted to receive (16r) and send (16s) digital signals between the actuator and the controller (16), wherein the digital signal includes one or more control signals received by the actuator (16r) from the controller (16).

[0054] In such a device, the downstream feed channels (17, 19, 160, 940c, 941c, 942c) may be adapted to convey the injection material to another downstream channel (160, 942c2) having a channel axis (Y, Z) which is non - coaxial with the linear travel path (XX) of the valve pin.

[0055] In another aspect of the present invention, there is provided an injection molding apparatus (1), comprising: an injection molding machine (500); a manifold (15) which receives injection material (13) from the injection molding machine (500) under pressure; a mold (25, 27, 300) having a cavity (5, 30) and at least one valve, the valve comprising: an actuator (14, 940, 941, 942) including a rotor (940r, 941r, 942r) capable of being controllably rotated by electricity, the actuator (14, 940, 941, 942) being interconnected with a controller (16) which generates a drive signal (DC); an electric drive device (940d, 941d, 942d) including an interface which receives the drive signal (DC) and controllably distributes electrical energy or power to a driver (940dr, 941dr, 942dr) driving the rotor (940r, 941r, 942r) in a controllably variable amount according to the drive signal (DC); a valve pin (1040, 1041, 1042) including a shaft having an axis (X) and a control surface (43, 45, 102m), the valve pin being interconnected with the rotor at an upstream end in an arrangement, wherein the valve pin is controllably driven upstream and downstream along a linear travel path (XX) through a downstream feed channel (17, 19, 160, 940c, 941c, 942c) which feeds the injection material to and through a gate (7, 9, 32, 34, 36) leading to the cavity of the mold, the downstream feed channel having complementary surfaces (47, 103s) adapted to engage with the control surface (43, 45, 102m) such that the upstream reaction force applied to the valve pin (1040, 1041, 1042) is minimized.

[0056] In such an apparatus, the downstream feed channel preferably has complementary surfaces (47, 103s) which are adapted to engage with the control surface (43, 45, 102m) such that the upstream reaction force applied to the valve pin (1040, 1041, 1042) is minimized.

[0057] In such an apparatus, the downstream feed channel generally has complementary surfaces (47, 103s) which are adapted to engage with the control surface (43, 45, 102m) at a position upstream of and remote from the gate (32, 34, 36).

[0058] In such a device, the electric drive means (940d, 941d, 942d) may comprise either one or the other or both of digital signal receiving (16r) and transmitting (16s) means, wherein: the digital signal receiving and transmitting means are adapted to receive (16r) and transmit (16s) digital signals between the electric drive means (940d, 941d, 942d) and the controller (16) of the injection moulding device (10); and wherein the digital signal comprises one or more control signals, and wherein the one or more control signals are digital control signals received from the controller (16).

[0059] Such a device may comprise position sensors (POS, POS0, POS1, POS2) which send position signals (POS0s, POS1s, POS2s) indicating the position of the valve pins (1040, 1041, 1042) to the controller (16), the program comprising instructions which use the position signals to indicate that the actuator (14, 940, 941, 942) moves the valve pins (1040, 1041, 1042) to one or more predetermined positions during the course of the injection cycle.

[0060] In such a device, the actuator (940, 941, 942) and the controller (16) may be adapted to receive (16r) and transmit (16s) digital signals between the actuator and the controller (16), wherein the digital signal comprises one or more control signals received by the actuator (16r) from the controller (16).

[0061] In such a device, the downstream feed channels (17, 19, 160, 940c, 941c, 942c) may be adapted to convey the injection material to another downstream channel (160, 942c2) having a channel axis (Y, Z) which is non - coaxial with the linear travel path (XX) of the valve pin.

[0062] In another aspect of the present invention, there is provided an injection molding apparatus (1), comprising: an injection molding machine (500); a manifold (15) that receives an injection material (13) from the injection molding machine (500) under pressure; a mold (25, 27, 300) having a cavity (5, 30) and at least one valve, the valve comprising: an actuator (14, 940, 941, 942) including a rotor (940r, 941r, 942r) capable of being controllably rotated by electricity, the actuator (14, 940, 941, 942) being interconnected with a controller (16) that generates a drive signal (DC); an electric drive device (940d, 941d, 942d) including an interface that receives the drive signal (DC) and controllably distributes electrical energy or power to a driver (940dr, 941dr, 942dr) that drives the rotor (940r, 941r, 942r) in a controllably variable amount according to the drive signal (DC); a valve pin (1040, 1041, 1042) including a shaft having an axis (X) and a control surface (43, 45, 102m), the valve pin being interconnected with the rotor at its upstream end in an arrangement, wherein the valve pin is controllably driven upstream and downstream along a linear travel path (XX) through downstream feed channels (17, 19, 160, 940c, 941c, 942c) that deliver the injection material to and through gates (7, 9, 32, 34, 36) leading to the cavity of the mold, the downstream feed channels having complementary surfaces (47, 103s) adapted to engage the control surface (43, 45, 102m) at a position upstream of and remote from the gates (32, 34, 36) provided in the gates.

[0063] In such an apparatus, the downstream feed channels preferably have complementary surfaces (47, 103s) adapted to engage the control surface (43, 45, 102m) such that the upstream force of the reaction applied to the valve pin (1040, 1041, 1042) is minimized.

[0064] In such an apparatus, the downstream feed channels generally have complementary surfaces (47, 103s) adapted to engage the control surface (43, 45, 102m) at a position upstream of and remote from the gates (32, 34, 36) provided in the gates (32, 34, 36).

[0065] In such a device, the electric drive means (940d, 941d, 942d) may comprise either one or the other or both of digital signal receiving (16r) and sending (16s) means, wherein: the digital signal receiving and sending means are adapted to receive (16r) and send (16s) digital signals between the electric drive means (940d, 941d, 942d) and the controller (16) of the injection molding device (10); and wherein the digital signal comprises one or more control signals, wherein the one or more control signals are digital control signals received from the controller (16).

[0066] Such a device may comprise position sensors (POS, POS0, POS1, POS2) which send position signals (POS0s, POS1s, POS2s) indicating the position of the valve pins (1040, 1041, 1042) to the controller (16), the program comprising instructions which utilize the position signals to indicate that the actuator (14, 940, 941, 942) moves the valve pins (1040, 1041, 1042) to one or more predetermined positions during the course of the injection cycle.

[0067] In such a device, the actuator (940, 941, 942) and the controller (16) may be adapted to receive (16r) and send (16s) digital signals between the actuator and the controller (16), wherein the digital signal comprises one or more control signals received by the actuator (16r) from the controller (16).

[0068] In such a device, the downstream feed channels (17, 19, 160, 940c, 941c, 942c) may be adapted to convey the injection material to another downstream channel (160, 942c2) having a channel axis (Y, Z) which is non - coaxial with the linear travel path (XX) of the valve pin.

[0069] In another aspect of the present invention, there is provided an injection molding apparatus (1) comprising: an injection molding machine (500); a manifold (15) which receives injection material (13) from the injection molding machine (500) under pressure; a mold (25, 27, 300) having a cavity (5, 30) and at least one valve, the valve comprising: an actuator (14, 940, 941, 942) including a rotor (940r, 941r, 942r) capable of being controllably rotated by electricity, the actuator (14, 940, 941, 942) being interconnected with a controller (16) which generates a drive signal (DC); an electric drive device (940d, 941d, 942d) including an interface which receives the drive signal (DC) and controllably distributes electrical energy or power to a driver (940dr, 941dr, 942dr) driving the rotor (940r, 941r, 942r) in a controllably variable amount in accordance with the drive signal (DC); a valve pin (1040, 1041, 1042) including a shaft having an axis (X) and a control surface (43, 45, 102m), the valve pin being interconnected with the rotor at an upstream end in an arrangement, wherein the valve pin is controllably driven upstream and downstream along a linear travel path (XX) through a downstream feed channel (17, 19, 160, 940c, 941c, 942c) which feeds the injection material to and through a gate (7, 9, 32, 34, 36) leading to the cavity of the mold, the downstream feed channel having complementary surfaces (47, 103s) adapted to engage the control surface (43, 45, 102m). The electric drive (940d, 941d, 942d) includes one or the other or both of digital signal receiving (16r) and transmitting (16s) means, wherein: the digital signal receiving and transmitting means is adapted to receive (16r) and transmit (16s) digital signals between the electric drive (940d, 941d, 942d) of the injection device (10) and the controller (16); and wherein the digital signal includes one or more control signals, and one or more of the control signals are digital control signals received from the controller (16).

[0070] In such an apparatus, the downstream feed channel preferably has complementary surfaces (47, 103s) which are adapted to engage the control surface (43, 45, 102m) such that the upstream force of reaction applied to the valve pin (1040, 1041, 1042) is minimized.

[0071] In such an apparatus, the downstream feed channel typically has complementary surfaces (47, 103s) which are adapted to engage the control surface (43, 45, 102m) at a position upstream of and remote from the gate (32, 34, 36).

[0072] In such a device, the electric drive means (940d, 941d, 942d) may comprise one or the other or both of digital signal receiving (16r) and sending (16s) means, wherein: the digital signal receiving and sending means are adapted to receive (16r) and send (16s) digital signals between the electric drive means (940d, 941d, 942d) and the controller (16) of the injection moulding device (10); and wherein the digital signal comprises one or more control signals, and one or more of the control signals are digital control signals received from the controller (16).

[0073] Such a device may comprise position sensors (POS, POS0, POS1, POS2) which send position signals (POS0s, POS1s, POS2s) indicating the position of the valve pins (1040, 1041, 1042) to the controller (16), and the program comprises instructions which utilize the position signals to indicate that the actuator (14, 940, 941, 942) moves the valve pins (1040, 1041, 1042) to one or more predetermined positions during the course of the injection cycle.

[0074] In such a device, the actuator (940, 941, 942) and the controller (16) may be adapted to receive (16r) and send (16s) digital signals between the actuator and the controller (16), wherein the digital signal comprises one or more control signals received by the actuator (16r) from the controller (16).

[0075] In such a device, the downstream feed channels (17, 19, 160, 940c, 941c, 942c) may be adapted to convey the injection material to another downstream channel (160, 942c2) having a channel axis (Y, Z) which is non - coaxial with the linear travel path (XX) relative to the valve pin.

[0076] In another aspect of the present invention, there is provided an injection molding apparatus (1), comprising: an injection molding machine (500); a manifold (15) that receives an injection material (13) from the injection molding machine (500) under pressure; a mold (25, 27, 300) having a cavity (5, 30) and at least one valve, the valve comprising: an actuator (14, 940, 941, 942) including a rotor (940r, 941r, 942r) that can be controllably rotated by electricity, the actuator (14, 940, 941, 942) being interconnected with a controller (16), the controller (16) generating a drive signal (DC); an electric drive device (940d, 941d, 942d) including an interface that receives the drive signal (DC) and controllably distributes electrical energy or power to a driver (940dr, 941dr, 942dr) that drives the rotor (940r, 941r, 942r) in a controllably variable amount according to the drive signal (DC); a valve pin (1040, 1041, 1042) including a shaft having an axis (X), the valve pin being interconnected with the rotor in an arrangement at an upstream end (1041ue), wherein the valve pin can be controllably driven upstream and downstream by the actuator (14, 940, 941, 942) along a linear travel path (XX) through a downstream feed channel (940c, 941c, 942c), the valve pin and the downstream feed channel being adapted to engage with each other to change the rate or speed of the flow of the injection material flowing to and through a gate (7, 9, 32, 34, 36) leading to the cavity of the mold; a pressure sensor (PS0, PS1, PS1a, PS2, PS2a) that senses the pressure of the injection material in a channel (17, 19, 940c, 941c, 942c, 5011) upstream of the gate (7, 9, 32, 34, 36); a controller (16) including a program that receives a signal indicating the sensed pressure from the pressure sensor (PS0, PS1, PS1a, PS2, PS2a), the program generating an instruction based on the received signal sent to the actuator (14, 940, 941, 942) through the electric drive device (940d, 941d, 942d), the instruction controlling the engagement of the valve pin and the downstream feed channel to control the rate or speed of the flow of the injection material during an injection cycle; a position sensor (POS, POS0, POS1, POS2) that sends a position signal (POS0s, POS1s, POS2s) indicating the position of the valve pin (1040, 1041, 1042) to the controller (16), the program including an instruction that uses the position signal to instruct the actuator (14, 940, 941, 942) to move the valve pin (1040, 1041, 1042) to one or more predetermined positions during an injection cycle.

[0077] In such a device, the downstream feed channel preferably has complementary surfaces (47, 103s) adapted to engage with control surfaces (43, 45, 102m) such that the upstream forces of reaction exerted on the valve pins (1040, 1041, 1042) are minimized.

[0078] In such a device, the downstream feed channel generally has complementary surfaces (47, 103s) adapted to engage with control surfaces (43, 45, 102m) at a location upstream of and remote from the gates (32, 34, 36).

[0079] In such a device, the electric drive means (940d, 941d, 942d) may include one or the other or both of digital signal receiving (16r) and transmitting (16s) means, wherein: the digital signal receiving and transmitting means are adapted to receive (16r) and transmit (16s) digital signals between the electric drive means (940d, 941d, 942d) and the controller (16) of the injection moulding device (10); and wherein the digital signals include one or more control signals, one or more of which are digital control signals received from the controller (16).

[0080] Such a device may include position sensors (POS, POS0, POS1, POS2) which send position signals (POS0s, POS1s, POS2s) indicative of the position of the valve pins (1040, 1041, 1042) to the controller (16), the program including instructions which utilize the position signals to indicate that the actuator (14, 940, 941, 942) moves the valve pins (1040, 1041, 1042) to one or more predetermined positions during the course of the injection cycle.

[0081] In such a device, the actuator (940, 941, 942) and the controller (16) may be adapted to receive (16r) and transmit (16s) digital signals between the actuator and the controller (16), wherein the digital signals include one or more control signals received by the actuator (16r) from the controller (16).

[0082] In such a device, the downstream feed channels (17, 19, 160, 940c, 941c, 942c) may be adapted to convey injection material to another downstream channel (160, 942c2) having a channel axis (Y, Z) non - coaxial with the linear travel path (XX) of the valve pin.

[0083] In another aspect of the present invention, there is provided an injection molding apparatus (1), comprising: an injection molding machine (500); a manifold (15) that receives injection material (13) from the injection molding machine (500) under pressure; a mold (25, 27, 300) having a cavity (5, 30) and at least one valve, the valve comprising: an actuator (14, 940, 941, 942) including a rotor (940r, 941r, 942r) rotatable controllably by electricity, the actuator (14, 940, 941, 942) being interconnected with a controller (16) that generates a drive signal (DC), a valve pin (1040, 1041, 1042) including a shaft having an axis (X) and a control surface (43, 45, 102m), the valve pin being interconnected with the rotor at an upstream end in an arrangement, wherein the valve pin is controllably driven upstream and downstream along a linear travel path (XX) through a downstream feed channel (17, 19, 160, 940c, 941c, 942c), the downstream feed channel (17, 19, 160, 940c, 941c, 942c) feeding and passing the injection material through a gate (7, 9, 32, 34, 36) leading to the cavity of the mold, the downstream feed channel having complementary surfaces (47, 103s) adapted to engage with the control surface (43, 45, 102m), the drive signal indicating that the rotor (940r, 941r, 942r) controllably drives the control surface (43, 45, 102m) to one or more positions relative to the complementary surfaces (47, 103s) such that the rate or velocity of the flow of the injection material is controllably varied, the actuator (940, 941, 942) and the controller (16) being adapted to receive (16r) and transmit (16s) digital signals between the actuator and the controller (16), wherein the digital signals include one or more control signals received by the actuator (16r) from the controller (16).

[0084] In such an apparatus, the downstream feed channel preferably has complementary surfaces (47, 103s) adapted to engage with the control surface (43, 45, 102m) such that the upstream force of the reaction applied to the valve pin (1040, 1041, 1042) is minimized.

[0085] In such an apparatus, the downstream feed channel generally has complementary surfaces (47, 103s) adapted to engage with the control surface (43, 45, 102m) at a position upstream of and remote from the gate (32, 34, 36).

[0086] In such a device, the electric drive means (940d, 941d, 942d) may include one or the other or both of the digital signal receiving (16r) and sending (16s) means, wherein: the digital signal receiving and sending means are adapted to receive (16r) and send (16s) digital signals between the electric drive means (940d, 941d, 942d) and the controller (16) of the injection molding device (10); and wherein the digital signal includes one or more control signals, and one or more of the control signals are digital control signals received from the controller (16).

[0087] Such a device may include position sensors (POS, POS0, POS1, POS2) that send position signals (POS0s, POS1s, POS2s) indicating the positions of the valve pins (1040, 1041, 1042) to the controller (16), and the program includes instructions that utilize the position signals to indicate that the actuator (14, 940, 941, 942) moves the valve pins (1040, 1041, 1042) to one or more predetermined positions during the course of the injection cycle.

[0088] In such a device, the actuator (940, 941, 942) and the controller (16) may be adapted to receive (16r) and send (16s) digital signals between the actuator and the controller (16), wherein the digital signal includes one or more control signals received by the actuator (16r) from the controller (16).

[0089] In such a device, the downstream feed channels (17, 19, 160, 940c, 941c, 942c) may be adapted to convey the injection material to another downstream channel (160, 942c2) having a channel axis (Y, Z) that is non - coaxial with the linear travel path (XX) relative to the valve pin.

[0090] In another aspect of the present invention, there is provided an injection molding apparatus (1) comprising: an injection molding machine (500); a manifold (15) that receives injection material (13) from the injection molding machine (500) under pressure; a mold (25, 27, 300) having a cavity (5, 30) and at least one valve, the valve comprising: an actuator (14, 940, 941, 942) including a rotor (940r, 941r, 942r) that is controllably rotatable by electricity, the actuator (14, 940, 941, 942) being interconnected with a controller (16) that generates a drive signal (DC); a valve pin (1040, 1041, 1042) including a shaft having an axis (X) and a control surface (43, 45, 102m), the valve pin being interconnected with the rotor at an upstream end in an arrangement such that the valve pin is controllably driven upstream and downstream along a linear travel path (XX) through a downstream feed channel (17, 19, 160, 940c, 941c, 942c), the downstream feed channel delivering the injection material to and through a gate (7, 9, 32, 34, 36) leading to the cavity of the mold, the downstream feed channel having complementary surfaces (47, 103s) adapted to engage the control surface (43, 45, 102m), the drive signal indicating that the rotor (940r, 941r, 942r) controllably drives the control surface (43, 45, 102m) to one or more positions relative to the complementary surfaces (47, 103s) such that the flow rate or velocity of the injection material is controllably varied, the downstream feed channel (17, 19, 160, 940c, 941c, 942c) delivering the injection material to another downstream channel (160, 942c2) having a channel axis (Y, Z) that is non - coaxial with the linear travel path (XX) of the valve pin.

[0091] In such an apparatus, the downstream feed channel preferably has complementary surfaces (47, 103s) that are adapted to engage the control surface (43, 45, 102m) such that the upstream force of reaction applied to the valve pin (1040, 1041, 1042) is minimized.

[0092] In such an apparatus, the downstream feed channel typically has complementary surfaces (47, 103s) that are adapted to engage the control surface (43, 45, 102m) at a position upstream of and remote from the gate (32, 34, 36).

[0093] In such a device, the electric drive means (940d, 941d, 942d) may include one or the other or both of digital signal receiving (16r) and transmitting (16s) means, wherein: the digital signal receiving and transmitting means are adapted to receive (16r) and transmit (16s) digital signals between the electric drive means (940d, 941d, 942d) and the controller (16) of the injection molding device (10); and wherein the digital signal includes one or more control signals, and one or more of the control signals are digital control signals received from the controller (16).

[0094] Such a device may include position sensors (POS, POS0, POS1, POS2) that send position signals (POS0s, POS1s, POS2s) indicating the positions of the valve pins (1040, 1041, 1042) to the controller (16), and the program includes instructions that utilize the position signals to indicate that the actuator (14, 940, 941, 942) moves the valve pins (1040, 1041, 1042) to one or more predetermined positions during the course of the injection cycle.

[0095] In such a device, the actuator (940, 941, 942) and the controller (16) may be adapted to receive (16r) and transmit (16s) digital signals between the actuator and the controller (16), wherein the digital signal includes one or more control signals received by the actuator (16r) from the controller (16).

[0096] In such a device, the downstream feed channels (17, 19, 160, 940c, 941c, 942c) may be adapted to convey the injection material to another downstream channel (160, 942c2) having a channel axis (Y, Z) that is non - coaxial with the linear travel path (XX) relative to the valve pin.

[0097] In another aspect of the present invention, a method of performing a cycle of injection molding is provided, including operating any of the devices described herein. Description of the Drawings

[0098] The drawings contain reference numerals corresponding to the components and devices that appear in the above - mentioned summary of the invention and the following description.

[0099] Figure 1Is a schematic cross-section of an injection molding system that includes an electro-mechanical or electronic actuator interconnected with a shortened valve pin that does not have a downstream gate closing pin portion. The distal end of the shortened valve pin has a bulbous portion or protrusion that has a flow control surface that engages a complementary control surface of a flow channel at a selected location upstream of and remote from the gate to control the rate of flow of injection fluid upstream of the gate during the injection molding cycle. The electro-mechanical or electronic actuator is interconnected with an electronic drive control device mounted to the housing of the electro-mechanical or electronic actuator. The electronic drive control device receives digital control and other signals from a remotely mounted controller that contains a program that executes an algorithm for controlling the operation of the electro-mechanical or electronic actuator and the position of the valve pin within the flow channel during the injection cycle.

[0100] Figure 2 Is similar to Figure 1 Side cross-sectional schematic view of a sequential valve system similar to the system as a gate, showing three valves with extended pins and having an electro-mechanical or electronic actuator having a drive control mechanism integrated with the body or housing of the actuator that houses the rotor and rotor drive components of the actuator.

[0101] Figure 3 Is a cross-sectional view of an example of a valve pin assembly. The valve pin has an upstream protrusion having a control surface 102m that interfaces with a complementary inner surface 103s of a downstream flow channel that leads to the gate of a cavity. The upstream control surface of the pin is set in a flow open position relative to the complementary inner channel surface. And, at Figure 3 the position shown, the downstream pin or shaft extension 1041e of the pin 1041 is set in a gate closed or injection material stop position.

[0102] Figure 3A Is Figure 3 A close-up cross-sectional view of the throat, control surface 102m, and complementary channel surface 103s elements of a sub-assembly of

[0103] Figure 3B Is Figure 3 A close-up cross-sectional view of the distal valve and nozzle or gate end of a sub-assembly of

[0104] Figure 4 Is similar to Figure 3 view showing relative to Figure 3The valve pin assembly shown is positioned at an intermediate upstream location, where the rate of flow of the injection material is restricted by the engagement or interaction of the control surface 102m and the complementary surface 103s, and flow is enabled at the gate region 34, with the tip of the valve pin withdrawn upstream from the gate surface GS.

[0105] Figure 4A is Figure 4 A close-up cross-sectional view of the throat, control surface 102m, and complementary channel surface 103s elements of a sub-assembly view.

[0106] Figure 4B is Figure 4 A close-up cross-sectional view of the distal valve and nozzle or gate end of the view and the sub-assembly.

[0107] Figure 5 is similar to Figure 3 the view, showing the valve pin member relative to Figure 3 shown positioned at the throat closed position, where the rate of flow of the injection material is stopped by the mating of the maximum diameter portion or circumference of the control surface 102m with the complementary inner circumferential surface 103s, and flow is enabled at the gate region 34, with the tip of the valve pin withdrawn further upstream from the gate surface GS.

[0108] Figure 5A is Figure 5 An enlarged partial cross-sectional view of the throat, control surface 102m, and complementary channel surface 103s elements of the assembly.

[0109] Figure 5B is Figure 5 An enlarged partial cross-sectional view of the distal valve and nozzle or gate end of the sub-assembly.

[0110] Figure 5C is an enlarged partial cross-sectional view of a portion of a curved flow channel formed by the mating of a hole in an insert or bushing 40i with a flow channel formed within a heated manifold 40. In this embodiment, a valve pin 107t is provided having a ball or control member 102 with a control surface 102t and a maximum diameter section having an outer circumferential surface 102mds that mates with the complementary inner surface 103s of the flow channel. In Figure 5C the view, the valve pin is positioned at an axial location where the maximum diameter circumferential surface 102mds is aligned and mated with the complementary surface, causing the flow of the injection material to stop.

[0111] Figure 5D is similar to Figure 5C the view, showing the valve pin relative to Figure 5Cis positioned downstream of the throat 103t, and the valve pin is in an axial position where the control surface 102t of the pin is in an axial position forming a clearance 102g that restricts the flow to less than the maximum flow rate that occurs when the protrusion 102 is fully moved downstream of the throat, where the flow is unrestricted. By moving the valve pin downstream from the Figure 5C position through a selected range of the downstream travel relative to the throat 103t, the rate of flow can be controllably varied.

[0112] Figure 5E is similar to Figure 5C and shows the Figure 5D opposite situation, where the valve pin is positioned upstream relative to the throat 103t such that the control surface 102t of the pin opens the flow passage when the pin moves upstream from the Figure 5C position, and by creating a restricted clearance 103g upstream of the throat 103t, 103td, a flow is produced at a restricted rate within a selected range of the upstream travel path, the restricted clearance 103g being restricted relative to the clearance produced when the pin is fully retracted upstream, where the control surface 102t is in a position to achieve maximum flow.

[0113] Figure 5F is an enlarged partial cross-sectional view of another embodiment upstream of the flow control pin surface and the complementary channel surface away from the gate, where the pin has a conical outer control surface that can be controllably set within a range of axial travel path positions relative to the inner channel surface 103s of a complementary conical configuration such that the size of the flow control clearance 102g can be controllably varied, thereby enabling the rate of flow of the injection material to be varied. In this embodiment, the linear travel axis XX of the valve pin 1041 is non-coaxial with the axis Y of the downstream flow channel 160, which conveys injection material from the channel 941c, where the valve pin 1041 is reciprocally driven along the axis XX.

[0114] Figure 5G is an enlarged partial cross-sectional view of another embodiment upstream of the flow control pin surface and the complementary channel surface away from the gate, where the pin has a conical outer control surface that can be controllably arranged within a range of axial travel path positions relative to the inner channel surface 103s of a complementary conical configuration such that the size of the flow control clearance 102g can be controllably varied, thereby enabling the rate of flow of the injection material to be changed. In this embodiment, the linear travel axis XX of the valve pin 1041 is non-coaxial with the axes Y, Z of the downstream flow channels 160, 941c2, which convey injection material from the channel 941c, where the valve pin 1041 is reciprocally driven along the axis XX.

[0115] Figure 6 A side cross-sectional view of an embodiment of an electro-actuator having an electric drive device mounted on, mounted to, or mounted within a housing of the actuator, and wherein a drive axis of the actuator is arranged non-coaxially with respect to a movement axis of a valve pin and is interconnected with a linear travel converter, the valve pin having a flow control ball or projection, complementary channel surfaces, and a controller having a programming routine designed to effect pin position control at least in part based on a match of the pressure within a flow channel to a predetermined pressure profile.

[0116] Figure 7 A side cross-sectional view of another embodiment of an electro-actuator having an electric drive device mounted on, mounted to, or mounted within a housing of the actuator, and wherein a drive axis of the actuator is arranged coaxially with respect to a movement axis of a valve pin, the valve pin having a flow control ball or projection, complementary channel surfaces, and a controller having a programming routine designed to effect pin position control at least in part based on a match of the pressure within a flow channel to a predetermined pressure profile.

[0117] Figure 8 A side cross-sectional view of another embodiment of an electro-actuator having an electric drive device mounted on, mounted to, or mounted within a housing of the actuator, and wherein a drive axis of the actuator is arranged non-coaxially with respect to a movement axis of a valve pin and is interconnected with a linear travel converter, the actuator housing being mounted to a top clamping plate, the valve pin having a flow control ball or projection, complementary channel surfaces, and a controller having a programming routine designed to effect pin position control at least in part based on a match of the pressure within a flow channel to a predetermined distribution of pressure.

[0118] Figure 9 A side cross-sectional view of another embodiment of an electro-actuator having an electric drive device mounted to, mounted on, or mounted within a housing of the actuator, wherein a drive axis of the actuator is arranged non-coaxially with respect to a movement axis of a valve pin and is interconnected to a linear travel converter, the actuator housing being mounted to a linear travel converter housing which in turn is mounted to a top clamping plate, the valve pin having a flow control ball or projection, complementary channel surfaces, and a controller having a programming routine designed to effect pin position control at least in part based on a match of the pressure within a flow channel to a predetermined pressure profile.

[0119] Figure 10Schematic side cross-sectional view of another embodiment of an electro - actuator having an electric drive device mounted to, attached to, or disposed within the housing of the actuator, wherein the drive axis of the actuator is arranged non - coaxially with respect to the movement axis of the valve pin and interconnected to a linear stroke converter, the actuator housing being mounted to a top clamping plate, the valve pin having a flow - control ball or projection, complementary channel surfaces, and a controller having a programming routine designed to effect pin - position control at least in part based on matching the pressure within the flow channel to a predetermined pressure profile.

[0120] Figure 11a An example of the injection - cycle profile of the pressure of the injection material measured at a position immediately downstream of the axial position within the fluid - delivery channel as described herein, where the control surface of the valve pin engages the complementary surface of the fluid - delivery channel to vary the control flow gap.

[0121] Figure 11b is similar to Figure 11a Another example of a similar profile.

[0122] Figure 11c is similar to Figure 11a Another example of a similar profile.

[0123] Figure 11d is similar to Figure 11a Another example of a similar profile.

[0124] Figure 12 An example of a user - interface display component and functional domain that enables a user to display, use, create, edit, and store a target pressure profile.

[0125] Figure 13 Another example of a user - interface display component and functional domain that enables a user to display, use, create, edit, and store a target pressure profile. Detailed Description

[0126] Figure 1 Schematic cross - sectional view of an injection - molding system including an electro - actuator or an electronic actuator interconnected to a valve pin having a flow - control surface that engages the surface of the flow channel at selected positions upstream of and remote from the gate to control the rate of flow of the injection fluid upstream of the gate during the cycle of injection molding, the electro - actuator or electronic actuator being interconnected to an electronic drive - control device mounted to the housing of the electro - actuator or electronic actuator, the electronic drive - control device receiving digital control signals and other signals from a remotely mounted controller, the remotely mounted controller containing a program that executes an algorithm to control the operation of the electro - actuator or electronic actuator and the position of the valve pin within the flow channel during the injection cycle.

[0127] Figure 2 A sequential valve gated system is shown, which shows three valves with electric or electronic actuators that have drive control mechanisms integrated with the body or housing of the actuator, and the actuator houses the rotor and rotor drive components of the actuator.

[0128] Figure 1 、 Figure 2 An exemplary embodiment of an injection molding system according to the present invention is shown. The system shown is a multi-gated single-cavity system, in which the melt material 18 is injected into the cavities 5, 30 from the gates 32, 34, 36. The melt material 18 is injected from the barrel 500 of the injection molding machine 13 through the extended inlet 5011 and into the heated distribution manifolds 15, 40. The manifolds 15, 40 distribute the melt through the upstream channels 17, 19. Although a hot runner system for injecting plastic melt is shown, the present invention is applicable to other types of injection systems where controlling the rate at which material (e.g., metal or composite material) is delivered to the cavity is useful. The melt is distributed through the channels 17, 19 respectively and is respectively distributed into the holes 940c, 941c, 942c of the nozzles 20, 21, 23. The melt is ejected from the nozzles 20, 21, 23 and injected into the cavities 5, 30 (where the part is formed) formed by the templates 25, 27, 300. Although a multi-gated single-cavity system is shown, the present invention can be applied to, for example, multi-cavity systems.

[0129] The injection nozzles 20, 21, 23 are received in corresponding wells formed in the template. The nozzles are typically each located in a support ring that serves to align the nozzles with the gates 32, 34, 36 and isolate the nozzles from the mold. The upstream ends 1041ue of the valve pins 1040, 1041, 1042 are connected to the associated actuators 14, 940, 941, 942, and the actuators 14, 940, 941, 942 operate to drive the valve pins to reciprocate upstream and downstream through the delivery channels 940c, 941c, 942c. The valve pins are, for example, at the start of the injection cycle from Figure 3 、 Figure 3Bstarts to open from the fully closed position shown and returns to the fully closed position at the end of the cycle. During the cycle, the valve pin can be located at an intermediate position between the upstream open positions to reduce or increase the flow rate of the melt. In the illustrated embodiment, a protrusion or head 102 is provided between the upstream end 1041ue and the downstream end 1041de. The protrusion includes a tapered portion 102m that forms an adjustable variable gap CGu, CGd having surfaces 103s, 103s2 of the orifice of the delivery channel. By shifting the valve pin to increase or decrease the size of the gap, the flow of melt material to the gate is correspondingly increased or decreased. The valve pins 1040, 1041, 1042 can be at, for example Figure 5 , Figure 5A the selected upstream positions shown and, for example Figure 3 , 3B the fully downstream gate closed position shown to close and stop the flow of injection fluid 18. When the valve pins 1040, 1041, 1042 are closed in the downstream position, in Figure 3 , Figure 3B the illustrated embodiment, the downstream end 1041de can be configured as a tapered portion as shown that contacts and seals with a complementary tapered gate surface GS. In an alternative embodiment, the gate surface can be configured as cylindrical or other configurations to mate with the distal surface 1041de of the complementary cylindrical configuration of the valve pins 940c, 941c, 942c.

[0130] The melt flow rate is related to the material pressure sensed in the flow channel. Thus, using a controller 16, the rate of melt flow through the gates 32, 34, 36 and into the cavity can be controllably adjusted according to a predetermined desired pressure profile during a given injection molding cycle.

[0131] In one embodiment, Figure 3 , Figure 3A , Figure 3B , Figure 4 , Figure 4A , Figure 4B , Figure 5 , Figure 5A , Figure 5B , to reduce the rate or velocity of the flow of the melt 18, the pin 1041 can be retracted away from the gate or controllably driven upstream along a selected portion of a selected flow control travel path CP by actuators 940, 941, 942, such as Figure 4A , Figure 5Aas shown, thereby controllably reducing the width of the flow control gap CGd between the control surface 102m of the valve pin and the complementary control surfaces 103s of the holes of the downstream channels 940c, 941c, 942c. In this same embodiment, by controllably driving the valve pin downstream along a selected portion of the selected flow control travel path CP, the rate or velocity of the flow of the melt 18 can be controllably variably increased.

[0132] In an alternative embodiment, by controllably driving the valve pin upstream away from the gate along another selected portion of the selected flow control path Figure 3 , Figure 3A , Figure 3B , Figure 4 , Figure 4A , Figure 4B , Figure 5 , Figure 5A , Figure 5B the valve pin 1041 as shown, the rate or velocity of the flow of the melt 18 can be conversely controllably increased, wherein the other selected portion of the selected flow control path starts at the throat 103t and extends upstream to controllably increase the width of the flow control gap CGu between the valve pin control surface 102m and another complementary control surface of the holes of the downstream channels 940c, 941c, 942c. In this alternative embodiment, by controllably driving the valve pin downstream along the same alternative selected portion of the selected flow control path, the flow rate or velocity of the melt 18 is controllably variably decreased.

[0133] In Figures 3 - 5B the embodiment, the valve pin includes an extension portion (1041) extending downstream from the control surface (43, 45, 102m), and the valve pins (1040, 1041, 1042) and the downstream feed channels (17, 19, 160, 940c, 941c, 942c) are configured such that in a first downstream position, the distal end (1041de) of the valve pin closes the gate (32, 34, 36), and the interface between the control surface (43, 45, 102m) and the complementary surface (47, 103s) is not closed, as Figures 3 - 3B shown, and in a second upstream position, the distal end of the valve pin (1041de) does not close the gate (32, 34, 36), and the interface between the control surface (43, 45, 102m) and the complementary surface (47, 103s) is closed, as Figures 5 - 5B shown.

[0134] Material pressure transducers or sensors PS1, PS2, PS1a, PS2a can be used to sense the pressure of injection material 18 in delivery channels 940c, 941c, 942c or in fluid flow channels 17, 19 disposed within manifold 40 or within sleeves 940b1, 940b2, which sleeves 940b1, 940b2 have fluid delivery channels in communication with downstream fluid delivery channels 940c, 941c, 942c.

[0135] In operation, the pressure of material 18 is sensed by pressure sensors PS0, PS0a, PS1, PS2, PS1a, PS2a associated with each nozzle and transmitted in real time to a control system or controller 16. The controller 16 receives the pressure signals, compares them with a predetermined pressure profile during the injection cycle, and sends drive signals DC to electric drives 940d, 941d, 942d, which electric drives 940d, 941d, 942d controllably distribute electrical energy or power in a controllable variable amount to drives 940dr, 941dr, 942dr of rotors driving electro - actuators in accordance with the drive signals (DC). The controller includes a processor and instructions that generate the drive signals DC, which cause valve pins 1040, 1041, 1042 to be driven upstream or downstream within fluid delivery channels 940c, 941c, 942c to select positions during the injection cycle so that the pressure of material 18 measured in real time by sensors PS0, PS1, PS2 is adjusted to match or track a predetermined profile of a preferred cycle material pressure, such as in the example described with reference to FIG. 11 - Figure 13 described example.

[0136] Figures 5C - 5E An alternative melt flow controller embodiment is shown where pin 107t is slidably mounted within mounting channel 108m, which mounting channel 108m has a protrusion or bulbous portion 102 and no downstream needle extension that can close gate 34. In such an embodiment, control surfaces 43, 45, 102m and complementary surfaces of the flow channels upstream of and remote from the gate are the only mechanisms by which fluid flow is stopped at the start and end of the injection cycle by positioning pin 107t at the position as Figure 5C shown. Similar to the Figures 5 - 5C control surfaces 43, 45, 102m, Figures 5C - 5EThe control surfaces 43, 45, 102m have a diameter equal to the maximum diameter of the middle section 102md of the fluid contact member 102, such that the pin 107t can be fully retracted in the direction 107u from the manifold and bushing 108t and easily replaced without disassembling any part of the manifold or bushing 108t. The middle section 102md of the maximum diameter generally has the same or substantially the same diameter as the complementary flow-limiting throat surface 103s of the bushing 108t, such that when the two surfaces are mated, the flow stops.

[0137] In the specific examples described herein, the control surfaces 43, 45, 102m are shown as the circular circumferential surfaces of the spherical or spherical protrusions 102. The control surfaces 43, 45, 102m and their complementary channel surfaces 47, 103s can be configured to have any geometric shape other than circular, such as square, hexagonal, elliptical, etc., as long as the two surfaces can be mated or engaged with each other such that when the two surfaces are mated or engaged with each other, the flow of the injection material stops.

[0138] As Figure 5D , Figure 5E shown, the flow rate and the flow rate that determines the size of the gap 103g can be controllably changed by the upstream movement 107u ( Figure 5E ) or the downstream movement 107d ( Figure 5D ) of the pin 107t. The upstream movement 107u can form a gap 103g between the bushing surface 108g ( Figure 5E ) and the lower outer control surface 102t of the member 102. The downstream movement 107d ( Figure 5D ) can also form a gap 103g between the channel surfaces 103s, 108g and the upper part of the outer control surface 102t of the member 102. As described above, the movement of the pin 107t controlled by the controller 16 controls the size of the gap 103g and thus controls the flow rate from the upstream channel 160 to the downstream channel 162t, which leads to the downstream channels 190 or 200, etc. As Figures 5D - 5F shown, the axis X of the pin 107t is non-coaxial with the axis of the downstream hole or flow channel (such as channels 940c, 941c, 942c), and the axis of the downstream hole or flow channel leads to the gate at its distal end, such as gates 32, 34, 36.

[0139] Figure 5F Another embodiment of a valve with a pin is shown, where the pin is arranged non-coaxially with respect to the axis of the downstream channel that conveys fluid to the gate of the cavity of the mold. In Figure 5FIn an embodiment, the valve pin 107 has a protrusion 102 having an outer surface 102s complementary to a mating surface 103, the mating surface 103 being disposed downstream of the protrusion within the flow channel 160. When the two surfaces match, i.e., when the member 102 is in Figure 5F the position 102p shown by the dashed line in Figure 2 , the flow stops. Between the position 102p shown in Figure 5F and the solid line 102, the size of the gap 102g changes, and the rate of fluid flow varies according to the size of the gap. In this embodiment, the fluid flow rate decreases during the upstream movement 107u of the pin 107 in the forward facing upstream direction. Upstream movement of a fluid contacting member, pin, etc. means that the member moves against the direction of fluid flow or in the opposite direction of fluid flow. Downstream movement means that the member moves in the same direction as the fluid flow. Upstream movement that reduces and / or stops the flow rate is generally preferred. In

[0140] the described embodiment controls the rate of melt flow along a channel axis offset from a channel having an axis intersecting the gate and leading to the gate away from the gate, thus achieving control of the flow rate to multiple channels intersecting multiple gates. Controlling the melt flow away from the gate also enables positioning of pressure or other material state sensors away from the gate.

[0141] In Figure 3 , Figure 3A , Figure 3B , Figure 4 , Figure 4A , Figure 4B , Figure 5 , Figure 5A , Figure 5B , Figure 5C , Figure 5D , Figure 5E the embodiment, the diameter 103td of the throat surface 103ts intended to mate with the complementary mating outer peripheral surfaces 102md, 102mds of the pin 1041 has a maximum diameter of about 10 mm to 12 mm and preferably has a maximum diameter of about 8 mm to 9 mm, such that the upstream reaction force exerted on the pin by the injection fluid and upstream of the motor rotor is minimized, enabling the use of a smaller sized electric motor actuator. In Figures 5 - 5EIn an embodiment, the diameter 102pd of the mating surface 102mds of the pin 1041 is preferably adapted to be the same as or substantially the same as the diameter 103td of the flow control throat surface 103ts such that when the pin 1041 is positioned where the mating surface 102mds is axially aligned with the maximum diameter throat surface 103ts, the flow of injection material through the throat 103t and thus through the gate 34 is stopped or substantially stopped.

[0142] The controller 16 generally includes, for example, a PID controller and a CPU. The CPU can execute a PID (Proportional, Integral, Derivative) algorithm that compares the sensed pressure (at a given time) from a pressure sensor or transducer with a target pressure (at a given time). The CPU instructs the PID controller to instruct the electro - actuators via communication of control drive signals through the electro - drivers 940d, 941d, 942d to adjust the positions of the valve pins 1040, 1041, 1042 to reflect the target pressure at that given time.

[0143] Although in the disclosed embodiments, the sensed condition is preferably pressure, other sensed conditions related to the melt flow rate can also be used. For example, the position of the valve pin. Pressure is typically measured by a pressure transducer that directly or indirectly measures the pressure of the injection material, such as via measuring the load on the valve pin through a load cell. Alternatively, a position sensor can be used to feed back the sensed condition (position) to the PID controller. In the same manner as described above, the CPU will use the PID algorithm to compare the sensed condition with a programmed target position profile or the load profile of a particular gate of the mold cavity and adjust the valve pin accordingly.

[0144] A position sensor is used to generate a signal indicating the pin position. A sensor that directly senses the valve pin position, such as a Hall - effect sensor or an optical sensor, can be used. Alternatively, a sensor that detects the rotor position of the electro - actuator, such as an encoder, can be used to generate a position signal indicating the valve pin position.

[0145] As used in this application with respect to various monitoring and control systems, the terms "controller", "component", "computer", etc. are intended to refer to computer - related entities, which are hardware, a combination of hardware and software, software, or software in execution. For example, a component or controller can be, but is not limited to, a process running on a processor, a processor, an object, an executable program, an executing thread, a program, and / or a computer. As an illustration, both an application running on a server and the server can be components. One or more components can reside within a process and / or an executing thread, and a component can be located on one computer and / or distributed between two or more computers.

[0146] The method claimed in the present invention can also be shown as a flowchart of the process of the present invention. Although, for the purpose of simplifying the explanation, one or more methods shown in flowchart form are described as a series of actions, it should be understood and appreciated that the present invention is not limited by the order of the actions, because according to the present invention, some actions can occur in an order different from the order shown and described herein and / or simultaneously with other actions. For example, those skilled in the art will understand and appreciate that the method can alternatively be represented as a series of interrelated states or events, such as in a state diagram. In addition, not all of the actions shown may be required to implement the method according to the present invention.

[0147] In various embodiments of the present invention disclosed herein, the term "data" or other representations can be any sequence of symbols (commonly represented as "0" and "1") that can be input into a computer, stored and processed therein, or sent to another computer. As used herein, data includes metadata, descriptions of other data. The data written to a storage device can be data elements of the same size, or data elements of variable size. Some examples of data include information, program code, program state, program data, other data, etc.

[0148] As used herein, computer storage media, etc. include volatile and non-volatile, removable and non-removable media for storing information such as computer-readable instructions, data structures, program modules, or other data. Computer storage media includes RAM, ROM, EEPROM, flash memory or other memory technologies, CD-ROM, digital versatile disk (DVD) or other optical disk storage, magnetic tape cartridges, tapes, magnetic disk storage or other magnetic storage devices, or any other medium that can be used to store the desired information and can be accessed by a computer.

[0149] The methods described herein can be implemented in a suitable computing and storage environment, for example, in the context of computer-executable instructions that can run on one or more processors, microcontrollers, or other computers. In a distributed computing environment, for example, certain tasks are performed by remote processing devices linked by a communication network, and program modules can be located in both local and remote memory storage devices. The communication network can include a global area network, for example, the Internet, a local area network, a wide area network, or other computer networks. It should be understood that the network connections described herein are exemplary, and other means for establishing communication between computers can be used.

[0150] A computer may include one or more processors and memories, such as a processing unit, system memory, and a system bus, where the system bus couples system components including, but not limited to, the system memory and the processing unit. The computer may also include a disk drive and an interface to external components. Various computer-readable media may be accessed by the computer and include volatile and non-volatile media, removable and non-removable media. The computer may include various user interface devices, including a display screen, a touch screen, a keyboard, or a mouse.

[0151] As used herein, "controller" also refers to an electrical and electronic control device including a single enclosure or multiple enclosures (usually interconnected and communicating with each other), the enclosure containing all the individual electronic processing, memory, and electrical signal generation components necessary or desirable for performing and constructing the methods, functions, and devices described herein. Such electrical and electronic components include programs, microprocessors, computers, PID controllers, voltage regulators, current regulators, circuit boards, motors, batteries, and instructions for controlling any variable elements discussed herein, such as the length of time, the degree of electrical signal output, etc. For example, as the term is used herein, the components of a controller include programs, controllers, etc. that perform functions such as monitoring, warning, and initiating an injection molding cycle, which include control means that act as independent devices for performing conventional functions (such as sending signals to notify and direct individual injection valves or a series of interdependent valves to start injection, i.e., moving the actuator and associated valve pins from the gate closed position to the gate open position). Additionally, while fluid-driven actuators are employed in typical or preferred embodiments of the present invention, actuators powered by electrical or electronic motors or drive sources may alternatively be used as actuator components.

[0152] An injection molding machine IMM, 500, 13 typically includes a machine controller supplied by its own internal manufacturer, which generates a standardized start of the cyclic gate closing and cyclic gate opening and gate closing machine voltage signal VS, which is typically 0 volts for gate opening and typically 24 volts (or 0 volts and 120 volts respectively) for gate closing. The standardized machine voltage signal VS can be sent to a signal conversion device, which converts the injection molding machine voltage signal into a signal that can be used by the controller 16 and the electric drive devices (940d, 941d, 942d) of the electric actuator to cause the electric actuator to move the valve pin to the gate closing or gate opening actuator position. The controller (16) can utilize these injection cycle start and end signals together with the position signals (POS0s, POS1s, POS2s) of the valve pins 1040, 1041, 1042 generated by the position sensors (POS0, POS1, POS2) to instruct the electric actuators (940, 941, 942) to drive or move the valve pins to one or more predetermined positions, such as the cycle start or end positions. Alternatively, the controller can use the position signals to instruct the actuator to move or drive the valve pin to another intermediate position during the injection cycle, such as the position where the pin is used to control the rate of injection fluid flow or the pressure of the injection material, so that when the gate of the cavity closes before the cycle ends, the injection material remains at the "Pack" Phase pressure for a predetermined period of time.

[0153] The position sensor signals POS0s, POS1s, POS2s and their associated position sensors POS, PS0, PS1, PS2, PS0a, PS1a, PS2a can also be used as inputs to a set of instructions in the program contained in the controller 16, which operates based on the difference between the values of a target or predetermined pressure curve and the value of the real-time pressure sensed at any given time point during the injection cycle to correct or adjust the axial position of the valve pins 1040, 1041, 1042 by a predetermined degree upstream or downstream. The degree of adjustment or correction of the axial positioning of the valve pin, and thus the precise positioning of the control surfaces 102m, 102t, is the degree or amount of the travel distance required to decrease or increase the real-time pressure at any given time point during the injection cycle to match or approach the value of the predetermined target pressure. The degree of this adjustment distance is predetermined and is input into the program as a variable, which is used in the control program to send a movement adjustment signal from the controller 16 to the electric drives 940d, 941d, 942d of the actuator. The goal of this program is to instruct the actuator to drive the valve pin to an axial position during the entire injection cycle, which generates a sensed or real-time pressure of the injection material that as closely as possible matches the predetermined curve of the target pressure.

[0154] The program included in the controller (16) preferably includes instructions that utilize the position signals POS0s, POS1s, POS2s to direct the actuators (14, 940, 941, 942) to move the respective valve pins (1040, 1041, 1042) to one or more predetermined positions during the injection cycle, which may include one or more of the following: (a) the initial position of the valve pins (1040, 1041, 1042) at the start of the injection cycle, (b) the end position of the valve pins at the end of the injection cycle, and (c) one or more intermediate positions of the valve pins between the initial and end positions.

[0155] The program may include instructions that utilize the position signals (POS0s, POS1s, POS2s) to adjust the sensed axial position of the valve pin by a stroke distance or amount such that the control surfaces (102m, 102t) adjust the real-time pressure of the injection material one or more times during the injection cycle to a value that approximates or matches a predetermined target pressure value for one or more times during the injection cycle.

[0156] The program may include instructions for determining the travel distance using a predetermined error value. The predetermined error value generally corresponds to or is proportional to one or more of (a) the accuracy error of the sensed pressure value and (b) the numerical difference between the sensed pressure and the predetermined target pressure.

[0157] Figure 11a 、 Figure 11b 、 Figure 11c 、 Figure 11d A time-versus-pressure graph (235, 237, 239, 241) showing the pressures detected by four pressure transducers associated with four nozzles mounted in a manifold block (not shown). The four nozzles may be substantially similar to or the same as the nozzles shown in Figures 1 - 5C and include pressure transducers interconnected to the controller 16 as described herein. Figures 11a - 11d The graph of Figures 11a - 11d is generated on the user interface 214 such that the user can observe the tracking of the actual pressure versus the target pressure during the injection cycle in real time or after the cycle is completed.

[0158] In Figures 11a - 11dIn the example, after the valves associated with the other three curves (237, 239, and 241) open at 0.00 seconds, the valve pin associated with graph 235 opens sequentially at 0.5 seconds. In a system employing a pin configured with flow control protrusions (such as 102) and an associated flow control orifice surface (such as 103s), the flow control orifice surface is arranged upstream of and away from the gate together with the extended needle portion (such as extension 1041e). Just before the pin opens at the start of the cycle, the valve pin is in Figure 5 , Figure 5A , Figure 5B the position shown, such that the flow stops at throat 103t. At approximately 6.25 seconds at the end of the injection cycle, all four valve pins are in Figure 3 , Figure 3A , Figure 3B the position shown, where the flow of the injection material stops through the mating of the tip 1041de with the gate surface GS at the gate 34. During the injection (e.g., from 0.00 to 1.0 seconds in Figure 11b ) and packing (e.g., from 1.0 to 6.25 seconds in Figure 11b ) of the graph section, each valve pin is controlled to multiple positions (such as between Figure 3 and Figure 5 the Figure 4 , Figure 4A , Figure 4B ) to vary the pressure sensed by the pressure transducers PS0, PS1, PS1a, PS2, PS2a associated with each valve to track the target pressure.

[0159] Through the user interface 214, target profiles can be designed and any target profile can be changed using standard window-based editing techniques. These profiles are then entered into memory and used by the controller 16 to control the position of the valve pins. For example, Figure 12 shows an example of the distribution creation and editing screen icon 300 generated on the interface 214.

[0160] The screen icon 300 is generated by a window-based application executed on the interface 214. Alternatively, the icon can be generated on an interface associated with the controller 6. The screen icon 300 provides the user with the ability to create a new target profile or edit an existing target profile for any given nozzle and its associated cavity. The profile 310 includes (x, y) data pairs corresponding to time values 320 and pressure values 330, where the time values 320 and pressure values 330 represent the desired pressures sensed by the pressure transducers for the particular nozzle being profiled. Figure 12The screen icons shown in [figure] are shown in "basic" mode, where a limited set of parameters are input to generate a distribution. For example, in the foregoing embodiment, the "basic" mode allows the user to input the start time displayed at 340, the maximum fill pressure (also known as injection pressure) displayed at 350, the start of the packing time displayed at 360, the packing pressure displayed at 370, and the total cycle time displayed at 380.

[0161] The screen also allows the user to select the specific valve pins they control, displayed at 390, and the name of the part being molded is displayed at 400. Each of these parameters can be adjusted independently using standard window-based editing techniques, such as using the cursor to activate the up / down arrows 410, or by simply typing a value on the keyboard. When these parameters are input and modified, the distribution will be displayed on curve 420 according to the parameters selected at that time.

[0162] By clicking on the drop-down menu arrow 391, the user can select a different nozzle valve in order to create, view, or edit the distribution for the selected nozzle valve and the associated cavity. Also, a part name 400 can be input and displayed for each selected nozzle valve.

[0163] The newly edited profile can be saved individually in computer memory, or saved as a set of profiles for a group of nozzles injected into a specific single-cavity or multi-cavity mold. The term "Recipe" is used to describe a set of profiles for a specific mold, and at 430, the name of the specific configuration is displayed on the screen icon.

[0164] To create a new distribution or edit an existing one, first the user selects a specific nozzle valve in the valve group for the specific configuration set to be molded. The valve options are displayed at 390. The user inputs an alphanumeric name to be associated with the distribution being created, which for a series tooling mold can be referred to as the part name displayed at 400. Then the user inputs the time displayed at 340 to specify when injection starts. A specific valve pin may have a delay to open the valve pins in sequence and inject the molten material into different gates of the mold.

[0165] Then, the user inputs the fill (injection) pressure displayed at 350. In the basic mode, the slope from zero pressure to the maximum fill pressure is a fixed time, such as 0.3 seconds. The user then inputs the start of the packing time to indicate when the packing phase of the injection cycle starts. The slope from the fill phase to the packing phase is also a fixed time in the basic mode, such as 0.3 seconds.

[0166] The final parameter is the cycle time displayed at 380, where the user specifies when the packing phase (and the injection cycle) ends. The slope from the packing phase to zero pressure will be instantaneous when using the valve pins to close the gates, asFigure 13 In an embodiment, or slower in a thermal gate (see Figure 1 ), due to the residual pressure in the cavity, which will decay to zero pressure once the part solidifies in the cavity of the mold.

[0167] User input buttons 415 to 455 are used to save and load target distributions. Button 415 allows the user to close the screen. When this button is clicked, the current set of distributions will apply to the configuration being profiled. Cancel button 425 is used to ignore the current distribution change and revert to the original distribution and close the screen. Read Trace button 435 is used to load existing and saved target distributions from memory. The distribution can be stored in the memory contained within interface 215 or controller 210. Save Trace button 440 is used to save the current distribution. Read Group button 445 is used to load an existing configuration group. Save Group button 450 is used to save the current set of target distributions for a set of nozzle valve pins. Process Adjustment button 455 allows the user to change the PID settings (e.g., gain) of specific nozzle valves in the control area. A pressure range 465 for injection molding applications is also shown.

[0168] Button 460 allows the user to switch to the "Advanced" mode distribution creation and editing screen. The advanced distribution creation and editing screen is shown in Figure 13 . The advanced mode allows a greater number of distribution points to be inserted, edited, or deleted than the basic mode. As in the basic mode, when the distribution changes, the resulting distribution is displayed. The advanced mode provides greater profiling performance because the user can select numerical values for individual time and pressure data pairs. As shown in curve graph 420, the displayed distribution 470 is not limited to a single pressure for filling and packing as in the basic mode. In the advanced mode, individual (x, y) data pairs (time and pressure) can be selected anywhere during the injection cycle.

[0169] To create and edit distributions using the advanced mode, the user can select multiple times (e.g., 16 different times) during the injection cycle and select pressure values for each selected time. Using standard window-based editing techniques (arrow 475), the user assigns consecutive points along the distribution (shown at 478), assigns the specific time values shown at 480, and assigns the specific pressure values shown at 485.

[0170] Button 490 is used to select the next point on the distribution for editing. Prev button 495 is used to select the previous point on the distribution for editing. Delete button 500 is used to delete the currently selected point. When the delete button is used, two adjacent points will be redrawn, showing a straight line segment.

[0171] After the currently selected point, use the Add button 510 to add a new point, and at this point, enter the time and pressure values for the new point. When using the Add button, the two adjacent points will be redrawn, showing the two segments connected to the new point.

Claims

1. An injection molding device, comprising: an injection molding machine, a manifold arranged to receive injection material from the injection molding machine under pressure, a controller arranged to generate or cause the generation of a drive signal; and at least one electronically controllable valve configured to adjust its angle in response to receiving a valve control instruction to transfer at least some of the injection material into a cavity of a mold, the at least one electronically controllable valve having: an actuator having a rotor controllably rotatable by electricity, the actuator being interconnected with the controller, a driver arranged to drive the rotor; an electric drive device having an interface arranged to receive the drive signal and controllably distribute electrical energy to the driver in a controllably variable amount according to the drive signal, a valve pin having a shaft with an axis (X) and a control surface disposed at a selected position along the axis (X) of the shaft, the valve pin being interconnected to the rotor at its upstream end in an arrangement, wherein the valve pin is controllably driven upstream and downstream along a linear travel path through a downstream feed channel arranged to direct the injection material to and through a gate leading to the cavity of the mold, the downstream feed channel having a complementary surface disposed upstream of and remote from the gate, the complementary surface adapted to interface with the control surface to controllably change at least one of the rate and velocity of flow according to the controlled axial positioning of the control surface relative to the complementary surface of the downstream feed channel; a sensor arranged to sense in real time the pressure of the injection material, the sensor also arranged to transmit a signal indicative of the sensed pressure to the controller, wherein the controller receives the pressure signal indicative of the sensed pressure, compares the sensed pressure with a predetermined pressure profile during an injection cycle, and also transmits: the valve control instruction to controllably open the at least one electronically controllable valve to a certain extent during the injection cycle to generate a fluid pressure according to the predetermined pressure profile; and the drive signal to the electric drive device to drive the rotor of the actuator so as to select the position of the valve pin during the injection cycle such that the pressure of the injection material measured in real time is adjusted to match or track the predetermined profile of the cyclic material pressure.

2. The device according to claim 1, wherein the electric drive device is arranged to receive electrical energy from a power source and controllably distribute the received electrical energy to the driver in a controllably variable amount during an injection cycle.

3. The device according to claim 1, wherein the electric drive device includes a pulse width modulator (PWM) arranged to convert the received electrical energy into a reciprocating voltage waveform suitable for driving corresponding phase coils of the actuator.

4. The device according to claim 3, wherein The pulse width modulator (PWM) includes a three-phase inverter arranged to convert electrical energy received from an interface of the electric drive device into three reciprocating voltage waveforms, each of the three reciprocating voltage waveforms being adapted to drive a corresponding one of three phase coils of an actuator driver.

5. The apparatus according to claim 3, wherein, the electrical energy interface of the pulse width modulator (PWM) is coupled to a DC bus voltage source.

6. The apparatus according to claim 1, wherein, the interface of the electric drive device is adapted to receive one or more control signals from a controller of the injection molding device and convert electrical energy received from a power source into a reciprocating voltage waveform signal based on the one or more control signals.

7. The apparatus according to claim 1, wherein, the interface of the electric drive device includes a pulse width modulator (PWM) arranged to convert electrical energy received from a power source into a reciprocating voltage waveform based on one or more control signals.

8. The apparatus according to claim 1, wherein, the interface of the electric drive device is arranged to receive one or more control signals, the one or more control signals containing control information arranged to cause the pulse width modulator (PWM) to convert the received electrical energy into a reciprocating voltage waveform signal adapted to drive a corresponding phase coil of an actuator driver to adjust one or more of position, speed, and torque of an actuator rotor.

9. The apparatus according to claim 1, wherein, the interface of the electric drive device is arranged to receive an analog electrical signal.

10. The apparatus according to claim 1, wherein, the electric drive device includes a communication device having one or the other or both of a digital signal receiving device and a digital signal transmitting device, wherein the communication device is arranged to transfer digital control signals between the electric drive device and a controller of the injection molding device.

11. The apparatus according to claim 10, wherein, the digital control signals include one or more of a differential position command, a differential current command, and a differential speed command.

12. The apparatus according to claim 10, wherein, the communication device is adapted to receive digital signals from the actuator, the digital signals including one or more feedback signals corresponding to operation of one or more of the actuator and the actuator rotor.

13. The apparatus according to claim 12, wherein the one or more feedback signals include one or more of an incremental feedback signal and an absolute feedback signal.

14. The apparatus according to claim 1, wherein, the actuator has an actuator housing arranged to accommodate the rotor and the driver; wherein the actuator housing is mounted adjacent to or aligned with respect to a heated manifold to allow one or the other or both of the actuator housing and the electric drive device to be in thermal communication with or in contact with the heated manifold during an injection cycle.

15. The apparatus according to claim 1, wherein, The actuator has an actuator housing that is mounted on or to the clamping plate in thermal communication or heat communication with the heated manifold.

16. The apparatus according to claim 15, wherein, the actuator housing is interconnected to a linear stroke converter in an arrangement that allows the valve pin to be driven along a linear axis (X) that is non - coaxial with respect to the drive axis (y).

17. The apparatus according to claim 16, wherein, the linear stroke converter is mounted on or to one or the other or both of the heated manifold or the clamping plate.

18. The apparatus according to claim 16, wherein the linear stroke converter includes a converter housing that is mounted to the heated manifold in direct or indirect thermally conductive contact, and the actuator housing is connected to the converter housing in thermally conductive contact with the converter housing.

19. The apparatus according to claim 1, wherein, the valve pin has an upstream end coupled to the actuator and a downstream end that is arranged to close the gate when the valve pin moves downstream to the gate - closed position, wherein the control surface is disposed at a selected axial position intermediate the upstream and downstream ends, and the control surface is adapted to interact with the complementary surface to increase or decrease the rate of material flow based on the movement of the valve pin through a selected travel path.

20. The apparatus according to claim 1, wherein, the sensor is adapted to detect the pressure of the injected material at a position downstream of the control surface of the valve pin.

21. The apparatus according to claim 1, wherein, the complementary surface and the control surface have a maximum diameter or radial dimension of 10 mm to 12 mm.

22. A method of performing an injection - molding cycle, comprising: providing an injection - molding machine, injection - molding material under pressure; receiving the injection - molding material in a manifold; using a controller to direct the generation of a drive signal; and transferring at least some of the injection material through at least one valve into a cavity of a mold, the transfer including: receiving the drive signal at an interface of an electric drive device; controllably distributing electrical energy to a driver in a controllably variable amount, wherein the driver is arranged to drive an electrically driven rotor; providing a valve pin having a shaft with an axis (X) and a control surface disposed at a selected position along the axis (X) of the shaft, the valve pin being interconnected at its upstream end to the electrically driven rotor in an arrangement, wherein the valve pin is controllably driven upstream and downstream along a linear travel path through a downstream feed channel that is arranged to direct at least a portion of the injection material to and through a gate leading to the cavity of the mold, the downstream feed channel having a complementary surface that is disposed upstream of and remote from the gate and that is adapted to interface with the control surface; and Controllably change at least one of the rate of flow and the velocity of flow of at least a portion of the injection material based on a controlled axial positioning of the control surface relative to a complementary surface of the downstream feed channel, wherein the controllably changing includes: sensing in real time the pressure of the injection material; transmitting a pressure signal indicative of the sensed pressure to the controller; comparing the sensed pressure with a predetermined pressure profile during an injection cycle; controlling at least one electronically controllable valve to be controllably opened to a certain extent during the injection cycle to generate fluid pressure according to the predetermined pressure profile; and controlling an electric drive device according to the drive signal to drive an electric drive rotor of the actuator, so as to select the position of the valve pin during the injection cycle, such that the pressure of the injection material measured in real time is adjusted to match or track the predetermined profile of the cycle material pressure.

23. An injection molding system, comprising: an injection molding machine, a manifold arranged to receive injection material from the injection molding machine under pressure, a mold having a cavity; and at least one electronically controllable valve configured to adjust its angle in response to receiving a valve control instruction to deliver at least some of the injection material into the cavity of the mold, the at least one electronically controllable valve including: an actuator having a rotor controllably rotatable by electricity, a controller interconnected to the actuator, the controller arranged to cause the generation of a drive signal, an electric drive device arranged to receive the drive signal and further arranged to control the rotor according to the drive signal; anda valve pin having a shaft with an axis (X) and a control surface, the valve pin being interconnected to the rotor at an upstream end in an arrangement, wherein the valve pin is controllably drivable upstream and downstream along a linear travel path through a downstream feed channel that delivers the injection material to and through a gate leading to the cavity of the mold, the downstream feed channel having a complementary surface disposed upstream of and remote from the gate, the complementary surface adapted to engage the control surface at a position disposed upstream and remote from the gate, a sensor arranged to sense in real time the pressure of the injection material, the sensor further arranged to transmit a signal indicative of the sensed pressure to the controller, wherein the controller receives the pressure signal indicative of the sensed pressure, compares the sensed pressure with a predetermined pressure profile during an injection cycle, and further transmits: the valve control instruction to indicate that the at least one electronically controllable valve is controllably opened to a certain extent during the injection cycle to generate fluid pressure according to the predetermined pressure profile; and the drive signal to the electric drive device to drive the rotor of the actuator, so as to select the position of the valve pin during the injection cycle, such that the pressure of the injection material measured in real time is adjusted to match or track the predetermined profile of the cycle material pressure.

24. The system according to claim 23, wherein, ​ The complementary surface and the control surface are adapted to reduce the upstream force reacting on the valve pin.

25. The system according to claim 23, wherein, the electric drive means includes a pulse width modulator (PWM) arranged to convert received electrical energy into a reciprocating voltage waveform signal, the reciprocating voltage waveform signal being adapted to drive corresponding phase coils of the actuator.

26. The system according to claim 23, wherein, the actuator has an actuator housing arranged to receive the rotor and the driver; wherein the actuator housing is mounted adjacent to or in alignment with the heated manifold to allow one or the other or both of the actuator housing and the electric drive means to be in thermal communication with or in contact with the heated manifold during the injection cycle.

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