An integrated injection molding testing and recycling device for plastic water separators

Abstract

This invention provides an integrated injection molding, testing, and recycling device for plastic separators, relating to the field of plastic separators. The device includes a feeding device, an injection molding device, a molding device, a testing device, a crushing device, and a control system. The feeding device includes a mixing hopper, a return pipe connected to the mixing hopper, and a new material pipe. The mixing hopper is connected to the injection molding device, which is also connected to the molding device. The testing device includes a clamping mechanism and a flattening testing mechanism. The clamping mechanism is selectively connected to the molding device and the flattening testing mechanism, while the flattening testing mechanism is connected to the crushing device. The crushing device is connected to the return pipe. The control system is connected to the feeding device, injection molding device, molding device, testing device, and crushing device via signals. It enables online product testing, allowing for rapid adjustment of injection molding parameters, improving product quality and yield. After testing, the product is directly crushed and fed into the feeding device, thereby improving material utilization and reducing product costs.

Description

Technical Field

[0001] This invention relates to the field of plastic water separators, and more specifically, to an integrated injection molding testing and recycling device for plastic water separators. Background Technology

[0002] As living standards improve, people are paying more and more attention to health. As a result, the material requirements for water distributors in central water distribution systems are also becoming increasingly stringent. They must not only have smooth inner surfaces and low water flow resistance, but also ensure that no foreign matter is released during use, and maintain hygiene. Because traditional metal materials have rough inner surfaces after processing, they are prone to bacterial growth, dirt, and even the release of heavy metals, which can pollute the water. Therefore, some new engineering plastics, such as high-temperature plastics like PSU and PPSU, have been introduced into water distributor production lines.

[0003] Materials such as PSU and PPSU are environmentally friendly and hygienic, meeting food-grade requirements. Injection-molded products have smooth inner surfaces. However, these materials have high injection molding temperatures and poor raw material flowability. They are particularly difficult to mold, resulting in low yield rates, especially when producing complex and relatively large products like water distributors.

[0004] Improper injection molding processes directly affect product quality. The flattening performance of parts is a common method for testing product quality. For high-temperature plastics such as PSU and PPSU, the initial machine inspection is particularly important. In addition, regular inspections are also necessary. Currently, product testing is conducted in laboratories, which results in a certain degree of lag.

[0005] Current manufacturing processes require specialized crushers for processing and testing parts. After crushing, the parts are vibrated and screened to remove dust before recycling. This method places high demands on the crushing chamber and the surface of the parts to be crushed, ensuring they are not contaminated, otherwise the performance of the injection molded products will be affected.

[0006] Therefore, this application is hereby submitted. Summary of the Invention

[0007] The objectives of this invention include, for example, providing an integrated injection molding, testing, and recycling device for plastic separators, which enables online product testing, thereby rapidly adjusting injection molding parameters, improving product quality, and increasing the pass rate; products requiring adjustment or testing can be directly crushed after testing without needing to be transferred.

[0008] The material enters the feeding device and is added to the feed hopper in a certain proportion, thereby improving the material utilization rate and reducing product costs.

[0009] The embodiments of the present invention can be implemented as follows:

[0010] In a first aspect, the present invention provides an integrated injection molding, testing, and recycling device for a plastic water separator, comprising a feeding device, an injection molding device, a molding device, a testing device, a breaking device, and a control system. The feeding device includes a mixing hopper, a return pipe, and a new material pipe. The return pipe and the new material pipe are uniformly connected to the mixing hopper. The outlet of the mixing hopper is connected to the inlet of the injection molding device, and the outlet of the injection molding device is connected to the molding device. The testing device includes a clamping mechanism and a flattening test mechanism. The clamping mechanism is selectively connected to the molding device and the flattening test mechanism. The flattening test mechanism is connected to the breaking device, and the outlet of the breaking device is connected to the return pipe. The control system is signal-connected to the feeding device, the injection molding device, the molding device, the testing device, and the breaking device.

[0011] In an optional embodiment, the flattening test mechanism includes a base plate, a baffle, a support plate, a main clamp, and a branch clamp. The baffle and the support plate are both mounted on the base plate. The baffle and the support plate are arranged opposite each other to form a test cavity for placing the injection-molded sample. The support plate is slidably connected to the base plate to adjust the size of the test cavity. The main clamp is mounted on the base plate and located on both sides of the baffle. The branch clamp is mounted on the support plate.

[0012] In an optional embodiment, the main road clamp includes two opposing main road clamps, a first flattening cylinder for driving the main road clamps to clamp and flatten, and a first rotary cylinder for driving the main road clamps to rotate. The first flattening cylinder is connected to the main road clamps and is mounted on the first rotary cylinder. The branch road clamp is provided with multiple branch road clamps arranged side by side, a second flattening cylinder for driving the branch road clamps to clamp and flatten, and a second rotary cylinder for driving the branch road clamps to rotate. The second flattening cylinder is connected to the branch road clamps and is mounted on the second rotary cylinder.

[0013] In an optional embodiment, the tray is slidably connected to the base plate via a first sliding assembly. The first sliding assembly includes a first motor, a lead screw, and a slider. The first motor is connected to the lead screw, the slider is mounted on the lead screw and can slide relative to the base plate, and the tray is mounted on the slider.

[0014] In an optional embodiment, the tray is slidably connected to the slider via a second sliding assembly, the second sliding assembly including a second motor, a gear and a rack, the tray being mounted on the rack, the rack meshing with the gear, the gear being rotatably mounted on the slider, the second motor being connected to the gear, and the rack being perpendicular to the lead screw.

[0015] In an optional embodiment, the crushing device includes a crushing box, a screening box, a storage box, and a conveying box. The crushing box is equipped with a cutting tool assembly, the outlet of the crushing box is connected to the inlet of the screening box, the screening box is equipped with a vibrating screen, the discharge port of the screening box is connected to the storage box, the storage box is connected to the conveying box, and the conveying box is connected to the return pipe of the feeding device.

[0016] In an optional embodiment, the cutting tool assembly includes a plurality of first cutting tools, a plurality of second cutting tools, a crushing shaft, and a third motor. The size of the first cutting tools is larger than the size of the second cutting tools. The plurality of first cutting tools and the plurality of second cutting tools are alternately mounted on the crushing shaft in sequence. The third motor is drivenly connected to the crushing shaft. The distance between any two adjacent first cutting tools is greater than the distance between any two adjacent second cutting tools.

[0017] In an optional embodiment, the injection molding device includes an injection barrel, a screw, and an injection motor. The injection barrel is provided with a feeding seat and a nozzle. The feeding seat is connected to the discharge port of the mixing hopper, and the nozzle is connected to the molding device. The screw is disposed inside the injection barrel and is connected to the injection motor.

[0018] Preferably, the outer side of the injection molding barrel is divided into five sections from the nozzle to the material feeding seat. The outer side of the injection molding barrel is provided with segmented heating coils. The temperature of the nozzle section is 380-390℃, the temperature of the second section is 370-380℃, the temperature of the third section is 360-370℃, the temperature of the fourth section is 345-355℃, and the temperature of the fifth section is 335-345℃.

[0019] Preferably, the injection barrel is used for injection molding in a time-stage pressurization manner, wherein the injection pressure in the first stage is 100-110 bar, the injection pressure in the second stage is 110-120 bar, and the injection pressure in the third stage is 120-130 bar.

[0020] Preferably, the injection molding cylinder adopts a time-stage pressure reduction method for pressure holding, wherein the first stage pressure holding pressure is 110-120 bar, and the second stage pressure holding pressure is 100-110 bar.

[0021] In an optional embodiment, the detection method of the integrated injection molding detection and recycling equipment for the plastic separator includes:

[0022] S1. Set the original operating parameters of the equipment. The control system collects the actual initial data of the operation of each component of the equipment. When the actual value reaches the set value, it starts counting and adjusting the forming modulus N. After reaching the preset value, the detection device starts detection.

[0023] S2. When the inspection is qualified, the initial time is set to T1 and the molding number is N1. After the equipment is running normally, the production time is T2 and the molding number is N2. Before the production time reaches T2 or the molding number reaches N2, the default equipment parameters remain unchanged.

[0024] S3. If the test fails, the injection molding parameters are adjusted. The control system re-collects the actual initial data of the operation of each component of the equipment. When the actual value reaches the set value, the counting and adjustment of the molding module N begins. After reaching the preset value, the testing device starts testing. If the test is qualified, proceed to step S2. If the test fails, continue to step S3.

[0025] S4. When the equipment running time T2-T1 > the system set time difference T; or when the equipment produces a module N2-N1 > the system set time difference N, the detection device extracts the product for detection. If the detection is qualified, proceed to step S2; if the detection is unqualified, proceed to step S3.

[0026] In an optional implementation, whenever the injection molding parameters change, first count N molds, then take "N+1 mold" and "N+2 mold" for testing, and the flattening direction of the two tests is at a 90° angle;

[0027] Preferably, when the flattening results in two different directions are both greater than 95% of the stroke, the product is judged as qualified; when the flattening in one direction is less than 95% but greater than 80%, the product is judged as pending; if the flattening in one direction is less than 80% of the stroke, the product is judged as unqualified.

[0028] The beneficial effects of the embodiments of the present invention include, for example:

[0029] This invention provides an integrated injection molding, testing, and recycling equipment for plastic distributors. By incorporating a testing device, a crushing device, and a control system, it enables real-time online testing during the plastic distributor's production process and timely crushing of tested parts, saving manpower and resources. More importantly, it provides immediate feedback to the control system, facilitating adjustments to process parameters. The testing frequency can be set based on production quantity, running time, or operating status, ensuring greater reliability. Waste products are directly transferred from the testing device to the crushing device for direct crushing, avoiding contamination and saving on turnover. Furthermore, the residual heat from the recent injection molding process reduces the difficulty of crushing. The crushed material is directly recycled within the integrated injection molding, testing, and recycling equipment for the plastic distributor, preventing secondary pollution, improving utilization, and reducing product costs. This application's online testing provides direct feedback on test results, offering direct guidance for machine adjustments. The control system is connected to the feeding device, injection molding device, molding device, testing device, and crushing device, allowing for precise control of parameters at each stage and timely adjustment based on test feedback, improving product quality and increasing the pass rate. Attached Figure Description

[0030] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of the present invention and should not be regarded as a limitation on the scope. For those skilled in the art, other related drawings can be obtained based on these drawings without creative effort.

[0031] Figure 1 A schematic diagram of the integrated injection molding testing and recycling equipment for the plastic water separator provided in this application;

[0032] Figure 2 A schematic diagram of the structure of the plastic separator produced by the integrated injection molding testing and recycling equipment for the plastic separator provided in this application;

[0033] Figure 3 A schematic diagram of the flattening test mechanism of the integrated injection molding testing and recycling equipment for the plastic water separator provided in this application;

[0034] Figure 4 A schematic diagram of the structure of the flattening test mechanism provided in this application when it is used with a plastic water separator;

[0035] Figure 5 A graph showing the pressure versus flattening distance during a flattening test using the flattening testing mechanism provided in this application;

[0036] Figure 6A schematic diagram of the material breaking device of the integrated injection molding testing and recycling equipment for the plastic water separator provided in this application;

[0037] Figure 7 The functional logic diagram of the control system of the integrated injection molding detection and recycling equipment for the plastic water separator provided in this application.

[0038] Icon: 100 - Integrated injection molding testing and recycling equipment for plastic water separators;

[0039] 110 - Feeding device; 111 - Mixing hopper; 112 - Return pipe; 113 - New material pipe;

[0040] 120 - Injection molding unit; 121 - Injection barrel; 122 - Screw; 123 - Injection motor; 124 - Feeding seat; 125 - Nozzle; 126 - Segmented heating coil;

[0041] 130 - Molding device;

[0042] 140 - Detection device; 141 - Clamping mechanism; 142 - Flattening test mechanism; 143 - Base plate; 144 - Baffle; 1441 - Baffle cylinder; 145 - Support plate; 1451 - Test chamber; 146 - Main clamp; 1461 - Main chuck; 1462 - First flattening cylinder; 1463 - First rotary cylinder; 147 - Branch clamp; 1471 - Branch chuck; 1472 - Second flattening cylinder; 1473 - Second rotary cylinder; 148 - First sliding assembly; 1481 - First motor; 1482 - Lead screw; 1483 - Slider; 149 - Second sliding assembly;

[0043] 150 - Crushing device; 151 - Crushing box; 152 - Screening box; 153 - Storage box; 154 - Conveying box; 155 - Cutting tool assembly; 1551 - First cutter; 1552 - Second cutter; 1553 - Crushing shaft; 1554 - Third motor; 156 - Vibrating screen; 157 - Fan;

[0044] 160 - Control System;

[0045] 200 - Plastic manifold; 201 - Main line; 202 - Branch line; 203 - Main line core end; 204 - Branch line core end. Detailed Implementation

[0046] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. The components of the embodiments of the present invention described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.

[0047] Therefore, the following detailed description of the embodiments of the invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely to illustrate selected embodiments of the invention. All other embodiments obtained by those skilled in the art based on the embodiments of the invention without inventive effort are within the scope of protection of the invention.

[0048] It should be noted that similar labels and letters in the following figures indicate similar items. Therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures.

[0049] In the description of this invention, it should be noted that if terms such as "upper," "lower," "inner," or "outer" are used to indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, or the orientation or positional relationship in which the product of this invention is usually placed, they are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this invention.

[0050] Furthermore, the terms "first" and "second" are used only to distinguish descriptions and should not be interpreted as indicating or implying relative importance.

[0051] It should be noted that, where there is no conflict, the features in the embodiments of the present invention can be combined with each other.

[0052] Example

[0053] Please refer to Figure 1 This embodiment provides an integrated injection molding, testing and recycling device 100 for plastic water separators, including a feeding device 110, an injection molding device 120, a molding device 130, a testing device 140, a breaking device 150 and a control system 160.

[0054] The feeding device 110 is used to feed materials into the injection molding device 120. In this embodiment, the feeding device 110 includes a mixing hopper 111, a return pipe 112, and a new material pipe 113. The return pipe 112 and the new material pipe 113 are connected to the mixing hopper 111 for uniform mixing. The return pipe 112 returns the crushed material after the product has been tested back to the feeding device 110, which helps to improve material utilization and reduce product costs. In this application, the return pipe 112 and the new material pipe 113 can enter the mixing hopper 111 in a certain proportion. The mixing hopper 111 is equipped with a stirrer to mix the new and old materials. After mixing in the mixing hopper 111, the outlet of the mixing hopper 111 is connected to the inlet of the injection molding device 120.

[0055] The injection molding device 120 is used to heat and melt the material. The outlet of the injection molding device 120 is connected to the molding device 130, so as to inject the heated and melted material into the molding device 130. In this embodiment, the injection molding device 120 includes an injection barrel 121, a screw 122, and an injection motor 123. The injection barrel 121 is provided with a feeding seat 124 and a nozzle 125. The feeding seat 124 is connected to the outlet of the mixing hopper 111, and the nozzle 125 is connected to the molding device 130. The screw 122 is disposed inside the injection barrel 121 and is connected to the injection motor 123. The screw 122 is preferably made of all-hard steel, tempered and integrally quenched, with a hardness of 55-60 HRC.

[0056] The outer side of the injection barrel 121, from the nozzle 125 to the feed seat 124, is divided into five sections: nozzle section, second section, third section, fourth section, and fifth section. The outer side of the injection barrel 121 is provided with segmented heating coils 126. The temperature of the nozzle section is 380-390℃, the temperature of the second section is 370-380℃, the temperature of the third section is 360-370℃, the temperature of the fourth section is 345-355℃, and the temperature of the fifth section is 335-345℃.

[0057] Driven by the injection motor 123, the screw 122 moves the material into the mold cavity of the molding device 130. The injection barrel 121 uses a time-segmented pressurization method for injection and a time-segmented pressure reduction method for holding pressure. The injection is divided into multiple injection stages according to the injection volume. Since the mold cavity is empty at the beginning, the injection speed is fast. As the injection volume increases, the speed slowly decreases. That is, this application performs a rapid feeding and pressurization, pressure reduction and speed reduction holding operation. At this time, the injection pressure of the first stage is 100-110 bar, the injection pressure of the second stage is 110-120 bar, and the injection pressure of the third stage is 120-130 bar. The injection time is about 8-10 seconds, and the holding time is about twice the injection time. The holding pressure of the first stage is 110-120 bar, and the holding pressure of the second stage is 100-110 bar.

[0058] The molding device 130 is used to mold the plastic distributor 200. Its specific mold cavity structure is determined based on the specific structure of the plastic distributor 200. The molding device 130 in this application is a conventional device, and its specific structure is not described in detail. For the structure of the molded plastic distributor 200, please refer to [link to relevant documentation]. Figure 2 It includes a main road 201 and a branch road 202. The two ends of the main road 201 are respectively provided with a main road core end 203, and the branch road 202 is provided with multiple branch road core ends 204.

[0059] Please refer to the following: Figure 1 and Figure 3The detection device 140 is used to detect the plastic water separator 200 produced in the molding device 130, and to provide feedback on whether the current production parameters need to be adjusted based on the detection results.

[0060] Specifically, the detection device 140 in this application includes a clamping mechanism 141 and a flattening test mechanism 142. The clamping mechanism 141 is used to clamp the plastic water separator 200 formed on the molding device 130 onto the flattening test mechanism 142 for detection. The clamping mechanism 141 is selectively connected to the molding device 130 and the flattening test mechanism 142. The clamping mechanism 141 in this application can be, for example, a robotic arm.

[0061] The flattening test mechanism 142 is used to perform a flattening test on the test piece of the plastic water separator 200 held by the clamping mechanism 141. The flattening test mechanism 142 includes a base plate 143, a baffle 144, a support plate 145, a main clamp 146, and a branch clamp 147. The flattening test mechanism 142 is provided with a baffle cylinder 1441 for lifting the baffle 144. The baffle 144 and the support plate 145 are both installed on the base plate 143. The baffle 144 and the support plate 145 are arranged opposite each other to form a test cavity 1451 for placing the injection molded sample. The support plate 145 is slidably connected to the base plate 143 to adjust the size of the test cavity 1451. The main clamp 146 is installed on the base plate 143 and located on both sides of the baffle 144. The branch clamp 147 is installed on the support plate 145.

[0062] Please see Figure 3 and Figure 4 The main clamp 146 is used to clamp the main core end 203 of the plastic manifold 200, and the branch clamp 147 is used to clamp the branch core end 204 of the plastic manifold 200. In this application, the main clamp 146 includes two opposing main clamps 1461, a first flattening cylinder 1462 for driving the main clamps 1461 to clamp and flatten, and a first rotating cylinder 1463 for driving the main clamps 1461 to rotate. The first flattening cylinder 1462 is connected to the main clamps. 1461 is connected, and the first flattening cylinder 1462 is mounted on the first rotary cylinder 1463; the branch clamp 147 is provided with multiple branch clamps 1471 arranged side by side, a second flattening cylinder 1472 for driving the branch clamps 1471 to clamp and flatten, and a second rotary cylinder 1473 for driving the branch clamps 1471 to rotate. The second flattening cylinder 1472 is connected to the branch clamps 1471 and is mounted on the second rotary cylinder 1473.

[0063] The first flattening cylinder 1462 drives the main channel clamp 1461 to clamp and flatten the main channel core end 203 of the plastic distributor 200. The first rotating cylinder 1463 can drive the main channel clamp 1461 to rotate, thereby clamping and flattening the main channel core end 203 of the plastic distributor 200 in multiple directions. Similarly, the second flattening cylinder 1472 drives the branch channel clamp 1471 to clamp and flatten the branch channel core end 204 of the plastic distributor 200. The second rotating cylinder 1473 can drive the branch channel clamp 1471 to rotate, thereby clamping and flattening the branch channel core end 204 of the plastic distributor 200 in multiple directions. In this application, by setting the flattening direction, the stability is improved, the test results are more authoritative, and the arbitrariness and uncertainty of human testing are avoided.

[0064] This application employs various methods to achieve the sliding of the tray 145, including but not limited to lead screw and slider, gear rack, gear chain, slide rail, etc. Specifically, the tray 145 is slidably connected to the base plate 143 via a first sliding assembly 148. The first sliding assembly 148 includes a first motor 1481, a lead screw 1482, and a slider 1483. The first motor 1481 is connected to the lead screw 1482, and the slider 1483 is mounted on the lead screw 1482 and can slide relative to the base plate 143. The tray 145 is mounted on the slider 1483. Furthermore, in this application, the tray 145 can also move perpendicularly relative to the direction of the lead screw 1482 to adjust the position of the branch clamp 147 so that it faces the test piece, which also facilitates the placement of the test piece into the test chamber 1451. In this application, the support plate 145 is slidably connected to the slider 1483 via the second sliding assembly 149. The second sliding assembly 149 includes a second motor (not shown in the figure), a gear (not shown in the figure), and a rack (not shown in the figure). The support plate 145 is mounted on the rack, the rack meshes with the gear, the gear is rotatably mounted on the slider 1483, the second motor is connected to the gear, and the direction of the rack is perpendicular to the lead screw 1482.

[0065] During testing, the plastic manifold 200 is fixed in place. The main channel clamp 1461 and the branch channel clamp 1471 move closer to the core end of the plastic manifold 200 until they completely enclose the core end. Then, the test is started. The clamping plates on both sides of the main channel clamp 1461 and the branch channel clamp 1471 move closer to the core axis until they are in contact. During the flattening test of the plastic manifold 200, the interaction force between the clamping plates of the main channel clamp 1461 and the branch channel clamp 1471 and the flattening distance is shown in the curve (see [reference]). Figure 5 As the flattening distance increases, the interaction force gradually increases until the core of the plastic distributor 200 breaks and is damaged.

[0066] Furthermore, it should be noted that the specific position of the main channel clamp 146 in this application can be adjusted manually, for example, by using screws or other installation methods. During the production process of a single model, no adjustment is required, as its position is relatively fixed. When the specifications (e.g., length) of the plastic distributor 200 change, the main channel clamp 146 can be adjusted.

[0067] In this application, the flattening test mechanism 142 is a destructive testing mechanism. Products that have undergone flattening testing by the flattening test mechanism 142 need to be conveyed to the crushing device 150 for crushing. The flattening test mechanism 142 is connected to the crushing device 150.

[0068] Please see Figure 6 The crushing device 150 is used to crush the test pieces after testing by the flattening test mechanism 142 and then return them to the feeding device 110 for recycling. Specifically, the crushing device 150 includes a crushing box 151, a screening box 152, a storage box 153, and a conveying box 154. The crushing box 151 is equipped with a cutter assembly 155, which includes multiple first cutters 1551, multiple second cutters 1552, a crushing shaft 1553, and a third motor 1554. The size of the first cutters 1551 is larger than that of the second cutters 1552. The multiple first cutters 1551 and multiple second cutters 1552 are alternately installed on the crushing shaft 1553. The third motor 1554 is connected to the crushing shaft 1553 for transmission. The distance between any two adjacent first cutters 1551 is greater than the distance between any two adjacent second cutters 1552. The first cutters 1551 are sparse and large, and they bite first during crushing, mainly used for product wrapping and fixing during crushing; the second cutters 1552 are dense and small, used for precise crushing. In this application, both the first cutter 1551 and the second cutter 1552 are mounted on the crushing shaft 1553. The crushing shaft 1553 is rotated by a third motor 1554. Simultaneously, the first cutter 1551 and the second cutter 1552 rotate, engaging with the side wall of the crushing chamber 151 to crush the test piece. The outlet of the crushing chamber 151 is connected to the inlet of the screening chamber 152. A vibrating screen 156 is installed inside the screening chamber 152. The outlet of the screening chamber 152 is connected to the storage tank 153, which is connected to the conveying tank 154. The conveying tank 154 is connected to the return pipe 112 of the feeding device 110. The vibrating screen 156 is equipped with a fan 157 to blow away and separate powder and dust, ensuring the purity and quality of the recovered material. The crushed material in storage bin 153 is transferred to conveyor bin 154 according to a fixed quota. Conveyor bin 154 and new material bin are configured in a mixed ratio. The crushing device can be shared by multiple injection molding machines according to the actual layout of the workshop, thereby improving the utilization rate of the crushing device.

[0069] The control system 160 is used to control the entire equipment. Specifically, the control system 160 is connected to the feeding device 110, injection molding device 120, molding device 130, detection device 140 and breaking device 150 respectively. The control system 160 can also be equipped with a control panel, etc., to facilitate real-time monitoring and modification of the parameter signals in the feeding device 110, injection molding device 120, molding device 130, detection device 140 and breaking device 150.

[0070] Please see Figure 7 The testing methods for the integrated injection molding testing and recycling equipment 100 for plastic water separators include:

[0071] S1. Set the original operating parameters of the equipment. The control system 160 collects the actual initial data of the operation of each component of the equipment. When the actual value reaches the set value, the counting and adjustment of the forming module N begins. After the preset value is reached, the detection device 140 begins detection.

[0072] S2. When the inspection is qualified, the initial time is set to T1 and the molding number is N1. After the equipment is running normally, the production time is T2 and the molding number is N2. Before the production time reaches T2 or the molding number reaches N2, the default equipment parameters remain unchanged.

[0073] S3. If the test fails, the injection molding parameters are adjusted. The control system 160 collects the actual initial data of the operation of each component of the equipment again. When the actual value reaches the set value, the counting and adjustment of the molding module N begins. After the preset value is reached, the detection device 140 starts the test. If the test is qualified, proceed to step S2. If the test fails, continue to step S3.

[0074] S4. When the equipment running time T2-T1 > the system set time difference T; or when the equipment produces a module N2-N1 > the system set time difference N, the detection device 140 extracts the product for detection. If the detection is qualified, proceed to step S2; if the detection is unqualified, proceed to step S3.

[0075] In this application, the test results are fed back to the control system 160, which promptly adjusts the machine adjustment parameters. Based on previous adjustments and test results, the control system 160 provides feedback on the trend of the adjustment effect and offers a reference adjustment direction. After formal production begins, if the random inspection is passed, production continues and the count is reset; if the random inspection fails, the injection molding parameters are adjusted, and the machine adjustment verification is performed again. Simultaneously, the products before testing are isolated for further verification. As production progresses to a mass production level, the testing frequency can be adjusted based on the test results. When production gradually stabilizes, the number of tests can be reduced.

[0076] Product handling and judgment during the inspection process: Whenever the injection molding parameters change, first count the N molds, then take the "N+1 mold" and "N+2 mold" for inspection, with the flattening direction of the two inspections at a 90° angle. When the flattening results in two different directions are both greater than 95% of the stroke, the product is judged as qualified; when the flattening in one direction is less than 95% but greater than 80%, the product is judged as pending; if the flattening is less than 80% of the stroke in any one instance, the product is judged as unqualified. The stroke ratios (95%, 80%) mentioned here are only for illustration and can be adjusted according to the actual situation.

[0077] Flattening test pass / fail criteria: As the flattening amount of the product increases, the pressure on the product increases. When the product is damaged or broken, the pressure is released. If the two sides of the product under pressure are in contact and there is no obvious pressure release, it is considered passable, or 100% stroke passable. If pressure release occurs as flattening progresses, it is failable. When the flattening stroke reaches 80% of the total stroke, it is said that the 80% flattening stroke is failable.

[0078] Please see Figures 1-7The working principle of the integrated injection molding, testing, and recycling equipment 100 for a plastic distributor provided in this embodiment is as follows: After the material is mixed from the feeding device 110, it is discharged into the injection molding device 120. The injection molding device 120 heats the material and sprays it from the nozzle 125 into the molding device 130 to form a plastic distributor 200. The control system 160 controls the clamping structure of the detection device 140 according to a specific detection logic to clamp the part to be tested and place it on the flattening test structure. The flattening test structure adjusts the position of the support plate 145 to cooperate with and clamp the branch core end 204. Then, the first flattening cylinder 1462 and the second flattening cylinder 1472 are controlled to perform flattening tests on the main core end 203 and the branch core end 204. During the test, the plastic distributor 200 is fixed, and the main clamp 1461 and the branch clamp 1471 move closer to the core end of the plastic distributor 200 until the core is flattened. The core is wrapped at the end, and then the test is started. The clamping plates on both sides of the main chuck 1461 and the branch chuck 1471 move towards the core axis until they fit together. The test data is recorded. Then, the clamping structure continues to clamp the next test piece and places it on the flattening test structure. The flattening test structure adjusts the position of the support plate 145 to cooperate with and clamp the branch core end 204. Then, the first rotary cylinder 1463 and the second rotary cylinder 1473 are controlled to rotate the main chuck 1461 and the branch chuck 1471 by 90°. Then, the first flattening cylinder 1462 and the second flattening cylinder 1472 are controlled to perform the flattening test on the main core end 203 and the branch core end 204. When the flattening results in two different directions are both greater than 95% of the stroke, it is judged as a qualified product; when the flattening in one direction is less than 95% but greater than 80%, it is judged as a pending product; if the flattening is less than 80% of the stroke in one direction, it is judged as unqualified. The flattening test mechanism 142 feeds back the test results to the control system 160. The control system 160 adjusts its parameters or operates normally and performs random checks based on the test results. After all test pieces are completed, they are conveyed to the crushing device 150 for crushing. The crushing device uses a first cutter 1551 and a second cutter 1552 of different sizes and densities to crush the test pieces. After crushing, the pieces are screened by the screening box 152. Materials with qualified particle sizes are conveyed to the return pipe 112 of the feeding device 110 through the storage box 153 and the conveying box 154. The material above the vibrating screen 156 is blown by the blower 157, which can continue to crush it or blow away fine powder and dust to ensure the purity and quality of the recycled material.

[0079] In summary, this invention provides an integrated injection molding testing and recycling equipment 100 for plastic distributors. By incorporating a testing device 140, a crushing device 150, and a control system 160, it enables real-time online testing during the production process of the plastic distributor 200 and timely crushing of the tested parts, saving manpower and resources. More importantly, it provides immediate feedback to the control system 160, facilitating adjustments to process parameters. The testing frequency can be set based on production quantity, running time, or operating status, ensuring greater reliability. Waste products are directly transferred through the testing device 140 to the crushing device for direct crushing, avoiding contamination and saving on turnover. Furthermore, the residual heat from the recent injection molding process reduces the difficulty of crushing. The crushed material is directly recycled within the integrated injection molding testing and recycling equipment 100 for the plastic distributor, preventing secondary pollution, improving utilization, and reducing product costs. This application's online testing and direct feedback of test results provide direct guidance for machine adjustments. The control system 160 is connected to the feeding device 110, injection molding device 120, molding device 130, detection device 140 and breaking device 150 respectively. The control system 160 can accurately control the parameters of each stage and adjust them in a timely manner according to the feedback test results, thereby improving product quality and increasing the pass rate.

[0080] The above description is merely a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in the present invention should be included within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the scope of the claims.

Claims

1. An integrated injection molding testing and recycling device for plastic water separators, characterized in that, The device includes a feeding device, an injection molding device, a molding device, a detection device, a breaking device, and a control system. The feeding device includes a mixing hopper, a return pipe, and a new material pipe. Both the return pipe and the new material pipe are connected to the mixing hopper. The outlet of the mixing hopper is connected to the inlet of the injection molding device, and the outlet of the injection molding device is connected to the molding device. The detection device includes a clamping mechanism and a flattening test mechanism. The clamping mechanism is selectively connected to the molding device and the flattening test mechanism. The flattening test mechanism is connected to the breaking device. The outlet of the breaking device is connected to the return pipe. The control system is signal-connected to the feeding device, the injection molding device, the molding device, the detection device, and the breaking device. The flattening test mechanism includes a base plate, a baffle, a support plate, a main clamp, and a branch clamp. The baffle and the support plate are both mounted on the base plate. The baffle and the support plate are arranged opposite each other to form a test cavity for placing injection-molded samples. The support plate is slidably connected to the base plate to adjust the size of the test cavity. The main clamp is mounted on the base plate and located on both sides of the baffle. The branch clamp is mounted on the support plate. The main road clamp includes two opposing main road clamps, a first flattening cylinder for clamping and flattening the main road clamps, and a first rotary cylinder for rotating the main road clamps. The first flattening cylinder is connected to the main road clamps and is mounted on the first rotary cylinder. The branch road clamp includes multiple branch road clamps arranged side by side, a second flattening cylinder for clamping and flattening the branch road clamps, and a second rotary cylinder for rotating the branch road clamps. The second flattening cylinder is connected to the branch road clamps and is mounted on the second rotary cylinder.

2. The integrated injection molding, testing, and recycling equipment for plastic water separators according to claim 1, characterized in that, The tray is slidably connected to the base plate via a first sliding assembly. The first sliding assembly includes a first motor, a lead screw, and a slider. The first motor is connected to the lead screw, the slider is mounted on the lead screw and can slide relative to the base plate, and the tray is mounted on the slider.

3. The integrated injection molding detection and recycling equipment for plastic water separators according to claim 2, characterized in that, The tray is slidably connected to the slider via a second sliding assembly. The second sliding assembly includes a second motor, a gear, and a rack. The tray is mounted on the rack, and the rack meshes with the gear. The gear is rotatably mounted on the slider. The second motor is connected to the gear, and the direction of the rack is perpendicular to the lead screw.

4. The integrated injection molding, testing, and recycling equipment for plastic water separators according to claim 1, characterized in that, The crushing device includes a crushing box, a screening box, a storage box, and a conveying box. The crushing box is equipped with a cutting tool assembly. The outlet of the crushing box is connected to the inlet of the screening box. The screening box is equipped with a vibrating screen. The discharge port of the screening box is connected to the storage box. The storage box is connected to the conveying box. The conveying box is connected to the return pipe of the feeding device.

5. The integrated injection molding detection and recycling equipment for plastic water separators according to claim 4, characterized in that, The cutting tool assembly includes multiple first cutting tools, multiple second cutting tools, a crushing shaft, and a third motor. The size of the first cutting tools is larger than the size of the second cutting tools. The first cutting tools and the second cutting tools are alternately installed on the crushing shaft in sequence. The third motor is connected to the crushing shaft for transmission. The distance between any two adjacent first cutting tools is greater than the distance between any two adjacent second cutting tools.

6. The integrated injection molding, testing, and recycling equipment for plastic water separators according to claim 1, characterized in that, The injection molding device includes an injection barrel, a screw, and an injection motor. The injection barrel is provided with a feeding seat and a nozzle. The feeding seat is connected to the discharge port of the mixing hopper, and the nozzle is connected to the molding device. The screw is disposed inside the injection barrel and is connected to the injection motor.

7. The integrated injection molding detection and recycling equipment for plastic water separators according to claim 6, characterized in that, The outer side of the injection barrel, from the nozzle to the material feeding seat, is divided into five sections: nozzle section, second section, third section, fourth section, and fifth section. The outer side of the injection barrel is provided with segmented heating coils. The temperature of the nozzle section is 380-390℃, the temperature of the second section is 370-380℃, the temperature of the third section is 360-370℃, the temperature of the fourth section is 345-355℃, and the temperature of the fifth section is 335-345℃.

8. The integrated injection molding detection and recycling equipment for plastic water separators according to claim 6, characterized in that, The injection barrel is used for injection molding in a phased pressurization manner, wherein the injection pressure in the first stage is 100-110 bar, the injection pressure in the second stage is 110-120 bar, and the injection pressure in the third stage is 120-130 bar.

9. The integrated injection molding detection and recycling equipment for plastic water separators according to claim 6, characterized in that, The injection molding cylinder uses a time-stage pressure reduction method for pressure holding, wherein the first stage pressure holding pressure is 110-120 bar, and the second stage pressure holding pressure is 100-110 bar.

10. The integrated injection molding, testing, and recycling equipment for plastic water separators according to any one of claims 1-9, characterized in that, The testing method of the integrated injection molding testing and recycling equipment for the plastic water separator includes: S1. Set the original operating parameters of the equipment. The control system collects the actual initial data of the operation of each component of the equipment. When the actual value reaches the set value, it starts counting the forming modulus of the machine. After reaching the preset value, the detection device starts detection. S2. When the inspection is qualified, set the initial time to T1 and the molding number to N1. After the equipment is running normally, the default equipment parameters remain unchanged until the production time reaches T2 or the molding number reaches N2. S3. If the test fails, the injection molding parameters are adjusted. The control system re-collects the actual initial data of the operation of each component of the equipment. When the actual value reaches the set value, the counting and adjustment of the molding module begins. After the preset value is reached, the testing device starts testing. If the test is qualified, proceed to step S2. If the test fails, continue to step S3. S4. When the time difference T2-T1 during equipment operation is greater than the system-set time difference T, or when the modulus difference N2-N1 produced by the equipment is greater than the system-set modulus difference, the detection device extracts the product for detection. If the detection is qualified, proceed to step S2; if the detection is unqualified, proceed to step S3.

11. The integrated injection molding, testing, and recycling equipment for plastic water separators according to claim 10, characterized in that, Whenever the injection molding parameters change, first count the N molds, then take the "N+1 mold" and "N+2 mold" for testing. The flattening direction of the two tests is at a 90° angle.

12. The integrated injection molding, testing, and recycling equipment for plastic water separators according to claim 11, characterized in that, When the flattening results in two different directions are both greater than 95% of the travel, the product is judged to be qualified; when the flattening result in one direction is less than 95% but greater than 80%, the product is judged to be pending; if the flattening result in one direction is less than 80% of the travel, the product is judged to be unqualified.

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