Injection molding apparatus with cooled integrated actuator motor drive

Abstract

An injection molding apparatus (10) comprising: a heatable manifold (40) disposed to receive and to substantially maintain a molten injection fluid (18) at a selected temperature from a molding machine (13); one or more nozzles (20, 22, 24); a flow channel (19, 42, 44, 46) formed by at least one of the manifold and the one or more nozzles, the flow channel disposed to receive the molten injection fluid through the manifold and to deliver the molten injection fluid to a gate (32, 34, 36) of a mold cavity (30); an electrical drive (940d, 941d, 942d) having an interface disposed to receive and to dispense a controllably varying amount of electrical energy during an injection cycle; a valve pin (1040, 1041, 1042); an actuator (940, 941, 942) coupled to the valve pin and disposed to control a flow of the molten injection fluid to the mold cavity (30) by controllably moving the valve pin, the actuator having: a drive (940dr, 941dr, 942dr) disposed to receive the controllably varying amount of electrical energy from the electrical drive (940d, 941d, 942d) and to drive the actuator (940, 941, 942) in accordance with the controllably varying amount of electrical energy from the electrical drive; and an actuator housing (940h, 941h, 942h) housing the drive (940dr, 941dr, 942dr), wherein the electrical drive (940d, 941d, 942d) is housed within the actuator housing (940h, 941h, 942h), or is housed by the actuator housing (940h, 941h, 942h), or is mounted on or to the actuator housing by a drive seat (940ds, 941ds); a source (260, 125f) of a heat sink fluid; and at least one passage (25, 33, 125) formed in or proximate to one or the other or both of the actuator housing (940h, 941h, 942h) and the drive seat (940ds, 941ds) and in sealed interconnection with the source, wherein, contemporaneous with the injection cycle, the heat sink fluid flows through the at least one passage (25, 33, 125) in a flow that absorbs heat from one or the other or both of the actuator housing and the drive seat.

Description

[0001] Cross-references to related applications

[0002] This application claims priority to U.S. Provisional Application 63 / 122618, filed December 8, 2020, the disclosure of which is incorporated herein by reference in its entirety, as fully set forth herein.

[0003] This application also claims priority to U.S. Provisional Application 63 / 226779, filed July 29, 2021, the disclosure of which is incorporated herein by reference in its entirety, as fully set forth herein.

[0004] All of the following disclosures are incorporated herein by reference in their entirety, as fully described herein: U.S. Patent Nos. 5,894,025, 6,062,840, 6,294,122 (7018), 6,309,208, 6,287,107, 6,343,921, 6,343,922, 6,254,377, 6,261,075, 6,361,300 (7006), 6,419,870, 6,464,909 (7031), 6,062,840 (7052), 6,261,075 (7052US1), 6,599,116, 7,234,929 (7075US1), and 7,419,625. (7075US2), U.S. Patent No. 7569169 (7075US3), U.S. Patent No. 8297836 (7087), U.S. Patent Application No. 10 / 214118 (7006), filed August 8, 2002, U.S. Patent No. 7029268 (7077US1), U.S. Patent No. 7270537 (7077US2), U.S. Patent No. 7597828 (7077US3) U.S. Patent Application No. 09 / 699856 (7056), filed October 30, 2000; U.S. Patent Application No. 10 / 269927 (7031), filed October 11, 2002; U.S. Patent Application No. 09503832 (7053), filed February 15, 2000; U.S. Application No. 09 / 656846 (7060), filed September 7, 2000; and U.S. Application No. 09 / 656846 (7060), filed December 3, 2001. U.S. Application No. 10 / 006504 (7068), International Application WO2011119791 (7094) filed March 24, 2011, U.S. Application No. 10 / 101278 (7070) filed March 19, 2002, PCT Application No. PCT / US11 / 062099 (7100WO0) and PCT Application No. PCT / US11 / 062096 (7100WO0) filed March 19, 2002. U.S. Patent Nos. 8,562,336, 8,091,202 (7097US1), 8,282,388 (7097US2), 9,205,587 (7117US0), U.S. Application No. 15 / 432,175 (7117US2), filed February 14, 2017, U.S. Patent No. 9,144,929 (7118US0), and U.S. Publication No.20170341283 (7118US3), US Patent No. 9724861 (7129US4), US Patent No. 9662820 (7129US3), International Application WO2014172100 (7131WO0), Publication No. WO2014209857 (7134WO0), International Application WO2015066004 (7140WO0), Publication No. WO2015006261 (7135WO0), International Application Publication Application No. WO2016153632 (7149WO2), International Application Publication No. WO2016153704 (7149WO4), US Patent No. 9937648 (7135US2), US Patent No. 10569458 (7162US1), International Application WO2017214387 (7163WO0), International Application PCT / US17 / 043029 (7165WO0) filed on July 20, 2017, and other international applications filed on July 2, 2017. International application PCT / US17 / 043100 (7165WO1) filed on 0, and international applications PCT / US17 / 036542 (7163WO0) filed on June 8, 2017, as well as international application Nos. WO2018129015 (7169WO0), WO2018148407 (7170WO0), WO2018148407 (7171WO0), and WO2018175362 (7172WO0) filed on 0. International applications WO2018194961 (7174WO0), WO2018200660 (7176WO0), WO2019013868 (7177WO0), WO2019100085 (7178WO0), WO2020176479 (7185WO0), WO2021 / 034793 (7187WO0), WO2021080767 (7188WO0). Background Technology

[0005] Injection molding systems have been developed to execute injection molding cycles controlled by electric motor actuators installed to prevent overheating. Electrical drive systems and equipment, typically including or containing electrical interfaces, pulse width modulators, inverters, comparators, etc., are used in such prior art systems in relatively cool, insulated, or isolated locations or environments within, on, or around the system, isolated from direct thermal communication or contact with actuators or fluid distribution manifolds, which are typically heated to abnormally high or elevated temperatures. Summary of the Invention

[0006] According to the present invention, an injection molding apparatus is provided, comprising: A heatable manifold (40) is configured to receive molten injection fluid (18) from an injection molding machine (13) and substantially maintain the molten injection fluid at a selected temperature. One or more nozzles (20, 22, 24); Runners (19, 42, 44, 46) are formed by a manifold and at least one of one or more nozzles, and the runners are configured to receive molten injection fluid through the manifold and deliver the molten injection fluid to the gate (32, 34, 36) of the mold cavity (30). The electric actuators (940d, 941d, 942d) have an interface configured to receive and distribute electrical energy in a controllable and variable amount during the injection cycle. Valve pins (1040, 1041, 1042); Actuators (940, 941, 942), connected to valve pins and configured to control the flow of molten injection fluid to the mold cavity (30) by controllable movement of the valve pins, have: Drivers (940dr, 941dr, 942dr) are configured to receive controllably varying electrical energy from electric drivers (940d, 941d, 942d) and drive actuators (940, 941, 942) in response to the controllably varying electrical energy from the electric drivers; and Actuator housings (940h, 941h, 942h) housing actuators (940dr, 941dr, 942dr), wherein electric actuators (940d, 941d, 942d) are housed within, or housed by, the actuator housings (940h, 941h, 942h), or mounted on or to the actuator housing via drive mounts (940ds, 941ds); The source of the endothermic fluid (260, 125f); and At least one channel (25, 33, 125) is formed in or near one or both of the actuator housing (940h, 941h, 942h) and the drive seat (940ds, 941ds) and is interconnected with a source seal, wherein, concurrent with the injection cycle, the heat-absorbing fluid passes through at least one channel (25, 33, 125) in a flow that absorbs heat from one or both of the actuator housing and the drive seat.

[0007] In this device, the drive housing (940ds, 941ds) is mounted in thermal communication with the actuator housing (940h, 941h, 942h).

[0008] One or both of the actuator housing (940h, 941h, 942h) and the electric drive (940d, 941d, 942d) are typically in substantial thermal communication with the heated manifold (40).

[0009] At least one channel (25, 33, 125) may be provided within a heat-conducting housing (940ds, 941ds), which may be installed in thermal communication with the actuator housing (940h, 941h, 942h).

[0010] The thermally conductive housing (940ds, 941ds) can be adapted to be easily attached to the actuator housing (940h, 941h, 942h) or detached from the actuator housing (940h, 941h, 942h).

[0011] At least one channel (25, 33, 125) may be provided in a heat-conducting seat (940mc, 940mc1, 940mc2, 941mc, 942mc), which is installed to be in thermal communication or contact with the heatable manifold (40).

[0012] The heat-conducting mounts (940mc, 940mc1, 940mc2, 941mc, 942mc) can be adapted to be easily connected to or detached from the heatable manifold (40).

[0013] One or more of the actuator housing (940h, 941h, 942h) and the electric actuator (940d, 941d, 942d) can be mounted to be in thermal communication or contact with the thermally conductive base (940mc, 940mc1, 940mc2, 941mc, 942mc).

[0014] One or more of the actuator housing (940h, 941h, 942h) and the electric drive (940d, 941d, 942d) may be adapted to be easily connected to or detached from the heat-conducting base (940mc, 940mc1, 940mc2, 941mc, 942mc).

[0015] The aforementioned device may also include a linear stroke converter (15) interconnected with the actuators (940, 941, 942) in the arrangement, allowing the valve pins (1040, 1041, 1042) to be driven along a linear axis (X), which may be non-coaxial or coaxial with respect to the drive axis (Y) of the actuator.

[0016] In such a device, at least one channel (25, 33, 125) may be disposed within a heat-conducting base (940mc, 940mc1, 940mc2, 941mc, 942mc), the heat-conducting base being mounted to be in thermal communication or contact with a heatable manifold (40), wherein a linear stroke converter (15) is adapted to be mounted to be in thermal communication with the heat-conducting base (940mc, 940mc1, 940mc2, 941mc, 942mc).

[0017] In such embodiments, the linear stroke converter (15) is typically adapted to be easily connected to the heat-conducting base (940mc, 940mc1, 940mc2, 941mc, 942mc) and detachable from the heat-conducting base.

[0018] In such devices, the actuator typically also includes: Drive components (150, 940l, 940ld); and The drive mechanism is a transmission device (190, 191) that allows the driver (100, 200, 940dr, 941dr, 942dr) to linearly drive the drive member (150) through the rotor (250, 940r, 941r, 942r) or a linear drive mechanism (940dr, 940ld) that allows the driver to directly linearly drive the drive member (940ld).

[0019] One or the other or both of the actuator housing (940h, 941h, 942h) and the drive housing (940ds, 941ds) are generally at least partially made of metallic material and can be mounted in substantially direct metal-to-metal thermal communication or contact with the heatable manifold (40).

[0020] One or both of the actuator housing (940h, 941h, 942h) and drive seat (940ds, 941ds) can be mounted in substantially direct metal-to-metal thermal communication or contact with the heatable manifold (40) by means of a seat (60, 60s) made of insulating or thermally conductive material.

[0021] The electric drivers (940d, 941d, 942d) typically include a pulse width modulator (PWM) that converts the received electrical energy into a reciprocating voltage waveform signal suitable for driving the corresponding phase coils of the driver (940dr, 941dr, 942dr).

[0022] Linear stroke converters typically also include: The converter housing (120, 940lh) is mounted to be in direct or indirect thermal communication with the heatable manifold (40) and the actuator housing (940h, 941h, 942h).

[0023] The device described above also includes: One or more sensors (950, 951, 952) are configured to generate one or more sensor signals to indicate one or more of the following: Rotational position of actuators (940, 941, 942); Linear position of actuators (940, 941, 942); The positions of the valve pins (1040, 1041, 1042) associated with the actuators (940, 941, 942); The pressure of the molten injection fluid (18) within the flow channel (19); The temperature of the molten injection fluid (18) within the flow channel (19) of the heatable manifold (40); The pressure of the molten injection fluid (18) within the nozzle channels (42, 44, 46); The temperature of the molten injection fluid (18) within the nozzle channels (42, 44, 46); The pressure of the molten injection fluid (18) within the mold cavity (30); The temperature of the molten injection fluid (18) within the mold cavity (30); The pressure of the molten injection fluid (18) inside the barrel of the injection molding machine (13); and The temperature of the molten injection fluid (18) inside the barrel of the injection molding machine (13); and An actuator controller (16) is configured to respond to at least one of one or more sensor signals to direct at least one operation of an actuator (5, 940, 941, 942) or its associated valve pin (1040, 1041, 1042), the at least one operation comprising: During the injection cycle, the device moves to a position corresponding to a predetermined profile, wherein the predetermined profile is associated with a set of injection fluid pressures, linear or rotary pin positions, linear actuator or valve pin positions, barrel screw positions, barrel pressures, or actuator drive fluid pressures corresponding to at least one of one or more sensor signals; or From the closed gate position upstream, exit at a reduced speed along the selected upstream travel path, and then exit at a higher speed than the reduced speed; or It travels downstream at a reduced speed along the selected downstream travel path, wherein the distal tip of the valve pin moves to the gate closed position; or Move upstream or downstream to an intermediate position between the gate closed position and the fully upstream position, wherein the valve pin remains in the intermediate position for a selected period of time during the injection cycle, and wherein, in the intermediate position, the distal tip of the valve pin restricts the flow rate of the molten injection fluid to be less than the maximum flow rate.

[0024] In another aspect of the present invention, an injection molding method is provided, comprising: Actuator housings (940h, 941h, 942h) suitable for supporting electric actuators (940d, 941d, 942d) are provided, wherein supporting the electric actuator includes mounting the electric actuator inside the actuator housing, or mounting the electric actuator on or to the actuator housing via a drive base (941ds, 942ds); Heating manifold (40); The manifold receives molten injection fluid (18) from the injection molding machine (13). Essentially, the molten injection fluid is maintained at a selected temperature; The molten injection fluid from the manifold is received in the flow path (19, 42, 44, 46) formed by the manifold (40) and at least one nozzle (20, 22, 24); The molten injection fluid is delivered to the gates (32, 34, 36) of the mold cavity (30). The electric actuators (940d, 941d, 942d) distribute a controllable amount of electrical energy to the actuators (940dr, 941dr, 942dr) during the injection cycle. The drive responds to controllable changes in electrical energy; The actuator moves the valve pins (1040, 1041, 1042) and thereby controls the flow of the molten injection fluid (18) into the mold cavity (30); Simultaneously, an injection cycle is performed, allowing the endothermic fluid (260) to pass through at least one channel (25, 33, 125), the at least one channel (25, 33, 125) being formed in or near one or both of the actuator housing (940h, 941h, 942h) and the drive seat (940ds, 941ds); and Heat is absorbed from one or the other, or both, of the actuator housing and the drive housing into the endothermic fluid (260).

[0025] In this method, the driving actuators (940, 941, 942) may include: Drive the drive component (150) along the linear drive axis (Y); and Drive valve pins (1040, 1041, 1042) along the non-coaxial pin shaft (X).

[0026] In this method, the driving actuators (940, 941, 942) may include: Drive the drive components (940l, 940ld) along the linear drive axis (X); and Drive valve pins (1040, 1041, 1042) along the coaxial pin shaft (X).

[0027] In another aspect of the invention, an injection molding apparatus (10) is provided, comprising an injection molding machine (13) that injects a flow of injection fluid (18) into a heating manifold (40), the heating manifold distributing the injection fluid (18) into channels for delivering the injection fluid to gates (32, 34, 36) of a mold cavity (30), the injection molding apparatus (10) comprising: The actuator (5, 940, 941r, 942r) includes a rotor (250, 940r, 941r, 942r) having a drive shaft (X, Y) and a driver (100, 200, 940dr, 941dr, 942dr) interconnected with the rotor (250, 940r, 941r, 942r). The driver is adapted to controllably drive the rotor to rotate about the drive shaft (X, Y). The driver (100, 200, 940dr, 941dr, 942dr) receives electrical energy or power from an electric driver (940d, 941d, 942d). The electric actuators (940d, 941d, 942d) include an interface that receives and controllably distributes a controllable amount of electrical energy or power during the injection cycle to the actuators (100, 200, 940dr, 941dr, 942dr). The actuator has an actuator housing (940h, 941h, 942h), which houses the rotor (250, 940r, 941r, 942r) and the driver (100, 200, 940dr, 941dr, 942dr), and the actuator housing is adapted to support the rotor (250, 940r, 941r, 942r). The electric actuators (940d, 941d, 942d) are housed within, or by, the actuator housing (940h, 941h, 942h), or mounted on or to the housing (940h, 941h, 942h) via the drive mount (940ds, 941ds); The actuator housing (940h, 941h, 942h) and drive seat (940ds, 941ds) include a pipe or channel (25) in the arrangement that is sealed to a source (260) of the heat-absorbing fluid (25f), such that the heat-absorbing fluid (25f) passes through the pipe or channel (25) in a flow that absorbs heat from one or both of the actuator housing (940h, 941h, 942h) and drive seat (940ds, 941ds).

[0028] In such a device, one or both of the actuator housing (940h, 941h, 942h) and the drive housing (940ds, 941ds) may be mounted or configured near or relative to the heating manifold (40) such that one or both of the housing (940h, 941h, 942h) and the electric drive (940d, 941d, 942d) are substantially in thermal communication or contact with the heating manifold (40).

[0029] Electrical actuators (5, 940, 941, 942) typically include a driver (100, 200, 940dr, 941dr, 942dr), which consists of one or more stators and an armature interconnected with a rotatably mounted rotor or shaft (250, 940r, 941r, 942r) such that when the driver (100, 200, 940dr, 941dr, 942dr) rotates when it applies and receives electrical energy or power, the rotor (250, 940r, 941r, 942r) rotates.

[0030] The drive (100, 200, 940dr, 941dr, 942dr) is typically interconnected with the rotor (250, 940r, 941r, 942r) and is adapted to controllably drive the rotor (250, 940r, 941r, 942r) to rotate around the drive shaft (X, Y).

[0031] The drives (100, 200, 940dr, 941dr, 942dr) typically receive electrical energy or power from the electric drives (940d, 941d, 942d).

[0032] Electric actuators typically receive electrical energy or power from a power source (PS) and controllably distribute the received electrical energy or power to the actuator in a controllable and variable amount (100, 200, 940dr, 941dr, 942dr) during the injection cycle.

[0033] The drive (100, 200, 940dr, 941dr, 942dr) is preferably adapted to drive the rotor (250, 940r, 941r, 942r) to rotate (940rt, 941rt, 942rt).

[0034] One or both of the actuator housing (940h, 941h, 942h) and the drive mount (940ds, 941ds) are typically heat-transferring or heat-conducting, such that the housing receives heat or thermal energy from the manifold (40), and the housing (940h, 941h, 942h) is in thermally conductive communication or contact with the manifold (40).

[0035] One or both of the actuator housing (940h, 941h, 942h) and the drive unit (940ds, 941ds) may be in direct or indirect thermal communication or contact with the heating manifold (40), such that one or both of the actuator housing (940h, 941h, 942h) and the electrical drive (940d, 941d, 942d) are substantially thermally or heat-contact with the heating manifold (40).

[0036] One or both of the actuator housing (940h, 941h, 942h) and the drive mounting base (940ds, 941ds) may be mounted on a base (60, 940mc) made of metal material, which is mounted in direct metal-to-metal thermal communication or contact with the heating manifold (40).

[0037] The electric actuators (940d, 941d, 942d) preferably include a pulse width modulator (PWM) that converts received electrical energy or power into sinusoidal voltage waveforms, each sinusoidal voltage waveform being adapted to drive a corresponding phase coil of the actuator driver (940dr, 941dr, 942dr).

[0038] A pulse width modulator (PWM) typically includes an inverter or a comparator.

[0039] A pulse width modulator (PWM) typically includes a three-phase inverter that converts electrical energy or power received from the interface into three sinusoidal voltage waveforms, each of which is adapted to drive a corresponding one of the three phase coils of an actuator driver.

[0040] Electrical energy or power received at or by a pulse width modulator (PWM) may include DC bus voltage.

[0041] The interface of the electric actuator (940d, 941d, 942d) is adapted to receive one or more control signals from the controller (16) of the injection molding apparatus (10) and convert the electrical energy or power received by the power supply (PS) into a sine wave based on one or more control signals.

[0042] The interface typically consists of a pulse width modulator (PWM), which converts electrical energy or power received from the power source into a sinusoidal waveform based on one or more control signals.

[0043] One or more control signals received by the interface may contain control information that causes the pulse width modulator (PWM) to convert the received electrical energy or power into a sine wave that is suitable for driving the corresponding phase coil of the actuator driver to adjust one or more positions, speeds or torques of the actuator rotor (250, 940r, 941r, 942r).

[0044] One or more control signals may include analog electrical signals received from the controller (16) at the electric drive.

[0045] The electric actuator (940d, 941d, 942d) may include one or both of a digital signal receiving (16r) and transmitting (16s) device, wherein: the digital signal receiving and transmitting device is adapted to receive (16r) and transmit (16s) digital signals between the electric actuator (940d, 941d, 942d) and the controller (16) of the injection molding apparatus (10); and wherein the digital signals include one or more control signals, wherein the one or more control signals are digital control signals received from the controller.

[0046] Digital control signals typically include one or more of the following: differential position command, differential current command, and differential speed command.

[0047] The digital signal receiving and transmitting device (16r, 16s) is preferably adapted to receive digital signals from the actuator, wherein: the digital signals received from the actuator include one or more feedback signals corresponding to one or more operations of the actuator and the actuator rotor.

[0048] A pulse width modulator (PWM) typically converts electrical energy or power received from an interface into a sinusoidal waveform that is adapted to actuate the corresponding phase coil of a driver, at least in part, based on one or more feedback signals.

[0049] One or more feedback signals received from the actuator typically include one or more of incremental feedback signals and absolute feedback signals.

[0050] The actuator housing (940h, 941h, 942h) of the actuator can be interconnected with the linear stroke converter (15, 940l, 941l, 942l) in an arrangement, wherein the valve pin (1040, 1041, 1042) is adapted to be driven along a linear axis (XX) that is not coaxial with the drive shaft (Y) of the rotor (250, 940r, 941r, 942r); the linear stroke converter (15) has linear drive members (940l, 941l, 942l) mounted on or in thermal communication with the heating manifold (40).

[0051] Linear stroke converters (15, 940l, 941l, 942l) are typically installed on one or both of the heating manifold (40) or clamps (80).

[0052] Linear stroke converters typically include a converter housing (120, 940lh) mounted in direct or indirect thermal contact with a heating manifold (40), and an actuator housing (940h, 941h, 942h) connected to and in thermal contact with the converter housing (120, 940lh).

[0053] Linear stroke converters typically include a converter housing (940lh) made of metallic material, which is mounted to be in direct metal-to-metal contact or communication with the heating manifold (40).

[0054] In such an embodiment, the linear stroke converter housing (940lh) is typically mounted on or to an active cooling seat (940mc, 940mc1), which is mounted on or to a heated or heatable manifold (40).

[0055] The actuator housing (940h, 941h, 942h) is typically mounted on or to the clamp (80) in the arrangement such that one or the other or both of the actuator housing (940h, 941h, 942h) and the electric actuator (940d, 941d, 942d) are in basic thermal or heat communication with the heating manifold (40).

[0056] In another aspect of the invention, an injection molding apparatus (10) is provided, comprising an injection molding machine (13) that injects injection fluid (18) into a heating manifold (40), the heating manifold distributing the injection fluid (18) into runners of gates (32, 34, 36) that deliver the injection fluid to a mold cavity (30), the injection molding apparatus (10) comprising: The actuator (5, 940, 941r, 942r) includes a rotor (250, 940r, 941r, 942r) having a drive shaft (X, Y) and a driver (100, 200, 940dr, 941dr, 942dr) interconnected with the rotor (250, 940r, 941r, 942r). The driver is adapted to controllably drive the rotor to rotate around the drive shaft (X, Y). The driver (100, 200, 940dr, 941dr, 942dr) receives electrical energy or power from an electric driver (940d, 941d, 942d). Electric actuators (940d, 941d, 942d) include an interface that receives and controllably distributes a controllable amount of electrical energy or power during an injection cycle into the actuators (100, 200, 940dr, 941dr, 942dr). The actuator has an actuator housing (940h, 941h, 942h), which houses the rotor (250, 940r, 941r, 942r) and the driver (100, 200, 940dr, 941dr, 942dr), and the actuator housing is adapted to support the rotor (250, 940r, 941r, 942r). The electric actuators (940d, 941d, 942d) are housed within, or by, the actuator housing (940h, 941h, 942h), or mounted on or attached to the actuator housing (940h, 941h, 942h) via drive mounts (940ds, 941ds).

[0057] The device includes a linear stroke converter (15, 940l, 941l, 942l), which is interconnected with a rotor (250, 940r, 941r, 942r) in an arrangement, wherein a valve pin (1040, 1041, 1042) is adapted to be driven along a linear axis (XX) that is not coaxial with the drive axis (Y) of the rotor (250, 940r, 941r, 942r); The linear stroke converter (15, 940l, 941l, 942l) includes a converter housing (120, 940lh, 941lh, 942lh) which includes a tube or channel (25) in which the heat-absorbing fluid (25f) is sealed in connection with a source (260) of the heat-absorbing fluid (25f) in an arrangement such that the heat-absorbing fluid (25f) passes through the tube or channel (125) in a flow that absorbs heat from the converter housing.

[0058] The linear stroke converters (15, 940l, 941l, 942l) can be mounted or installed on one or both of the heating manifold (40) or the clamp (80).

[0059] The linear stroke converter can be installed in direct or indirect thermal contact with the heating manifold (40), and the actuator housing (940h, 941h, 942h) is connected to and in thermal contact with the converter housing (120, 940lh).

[0060] The converter housing (940lh) is preferably made of metal material and is in direct metal-to-metal contact or communication with the heating manifold (40).

[0061] Electrical actuators (940, 941, 942) typically include a driver (100, 200, 940dr, 941dr, 942dr), which consists of one or more stators and an armature interconnected with a rotatably mounted rotor or shaft (940r, 941r, 942r) such that when the driver (940dr, 941dr, 942dr) rotates when it applies and receives electrical energy or power, the shaft (940r, 941r, 942r) rotates.

[0062] The rotors (940r, 941r, 942r) typically have drive shafts (X, Y), and drives (100, 200, 940dr, 941dr, 942dr) are interconnected with the rotors (940r, 941r, 942r) and adapted to controllably drive the rotors (940r, 941r, 942r) to rotate around the drive shaft Y.

[0063] The drives (100, 200, 940dr, 941dr, 942dr) typically receive electrical energy or power from the electric drives (940d, 941d, 942d).

[0064] Electric actuators typically receive electrical energy or power from a power source (PS) and controllably distribute the received electrical energy or power to the actuator in a controllable and varying amount during the injection cycle (100, 200, 940dr, 941dr, 942dr).

[0065] The drive (100, 200, 940dr, 941dr, 942dr) is preferably adapted to drive the rotor (250, 940r, 941r, 942r) to rotate (940rt, 941rt, 942rt).

[0066] One or both of the actuator housing (940h, 941h, 942h) and the drive housing (940ds, 941ds) are typically thermally conductive or heat-conducting, such that the housing receives heat or thermal energy from the manifold (40), and the housing (940, 941, 942h) is in thermally conductive communication or contact with the manifold (40).

[0067] One or both of the actuator housing (940h, 941h, 942h) and the drive housing (940ds, 941ds) are preferably in direct or indirect thermal communication or contact with the heating manifold (40), such that one or both of the actuator housing (940h, 941h, 942h) and the electric drive (940d, 941d, 942d) are substantially in thermal or heat-conducting communication or contact with the heating manifold (40).

[0068] One or both of the actuator housing (940h, 941h, 942h) and the drive housing (940ds, 941ds) are typically mounted on a seat made of metal material, which is mounted to be in direct metal-to-metal contact or communication with the heating manifold (40).

[0069] The electric actuators (940d, 941d, 942d) typically include a pulse width modulator (PWM), which converts the received electrical energy or power into a sinusoidal voltage waveform, each of which is suitable for driving the corresponding phase coil of the actuator driver (940dr, 941dr, 942dr).

[0070] The pulse width modulator (PWM) preferably includes an inverter or a comparator.

[0071] A 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 which is adapted to drive a corresponding one of the three phase coils of an actuator driver.

[0072] Electrical energy or power received at or by a pulse width modulator (PWM) may include DC bus voltage.

[0073] The interface of the electric actuator (940d, 941d, 942d) is adapted to receive one or more control signals from the controller (16) of the injection molding apparatus (10) and convert the electrical energy or power received by the power supply (PS) into a sine wave according to one or more control signals.

[0074] The interface typically consists of a pulse width modulator (PWM), which converts electrical energy or power received from the power source into a sinusoidal waveform based on one or more control signals.

[0075] The interface receives one or more control signals that typically contain control information that causes the pulse width modulator (PWM) to convert the received electrical energy or power into appropriate phase coils suitable for driving the actuator driver to adjust one or more positions, speeds, or torques of the actuator rotor (940r, 941r, 942r).

[0076] One or more control signals typically include analog electrical signals received from the controller (16) at the electric drive.

[0077] The electric drive (940d, 941d, 942d) typically includes one or both of a digital signal receiving (16r) and transmitting (16s) device, wherein: the digital signal receiving and transmitting device is adapted to receive (16r) and transmit (16s) digital signals between the electric drive (940d, 941d, 942d) of the injection molding machine (10) and the controller (16); and wherein the digital signals include one or more control signals, wherein the one or more control signals are digital control signals received from the controller.

[0078] Digital control signals typically include one or more differential position commands, differential current commands, and differential speed commands.

[0079] The digital signal receiving and transmitting device (16r, 16s) is preferably adapted to receive digital signals from the actuator, wherein: the digital signals received from the actuator include one or more feedback signals corresponding to one or more operations of the actuator and the actuator rotor.

[0080] A pulse width modulator (PWM) can convert electrical energy or power received from an interface into a sinusoidal waveform that is adapted to drive the corresponding phase coil of an actuator driver based at least in part on one or more feedback signals.

[0081] One or more feedback signals received from the actuator typically include one or more of incremental feedback signals and absolute feedback signals.

[0082] In another aspect of the invention, an injection molding apparatus (10) is provided, comprising an injection molding machine (13) that injects injection fluid (18) into a heating manifold (40), the heating manifold distributing the injection fluid (18) into runners of gates (32, 34, 36) that deliver the injection fluid to a mold cavity (30), the injection molding apparatus (10) comprising: The actuator (5, 940, 941r, 942r) includes a rotor (250, 940r, 941r, 942r) having a drive shaft (X, Y) and a driver (100, 200, 940dr, 941dr, 942dr) interconnected with the rotor (250, 940r, 941r, 942r). The driver is adapted to controllably drive the rotor to rotate around the drive shaft (X, Y). The driver (100, 200, 940dr, 941dr, 942dr) receives electrical energy or power from an electric driver (940d, 941d, 942d). The electric actuators (940d, 941d, 942d) include an interface that receives and controllably distributes a controllable amount of electrical energy or power in an injection cycle to the actuators (100, 200, 940dr, 941dr, 942dr). The electric actuators (940d, 941d, 942d) include a pulse width modulator (PWM) that converts the received electrical energy or power into sinusoidal voltage waveforms, each sinusoidal voltage waveform being adapted to drive a corresponding phase coil of the actuator actuator (100, 200, 940dr, 941dr, 942dr). The actuator has an actuator housing (940h, 941h, 942h), which houses the rotor (250, 940r, 941r, 942r) and the driver (100, 200, 940dr, 941dr, 942dr), and the actuator housing is adapted to support the rotor (250, 940r, 941r, 942r). The electric actuators (940d, 941d, 942d) are housed within, or by, the actuator housing (940h, 941h, 942h), or mounted on or to the housing (940h, 941h, 942h) via the drive mount (940ds, 941ds); The actuator housing (940h, 941h, 942h) and drive seat (940ds, 941ds) include a pipe or channel (25) in the arrangement that is sealed to a source (260) of the heat-absorbing fluid (25f), such that the heat-absorbing fluid (25f) passes through the pipe or channel (25) in a flow that absorbs heat from one or both of the actuator housing (940h, 941h, 942h) and drive seat (940ds, 941ds).

[0083] Such a device (10) typically also includes one or more sensors (950, 951, 952) that detect and generate one or more sensor signals indicating one or more rotational or linear positions of the actuator (5, 940, 941, 942) or its associated valve pins (1040, 1041, 1042), indicating pressure or temperature of injected fluid (18) within the flow channel (19) of the manifold (40) or nozzle channels (42, 44, 46), or within the cavity (30) of the mold (33) or within the barrel of the injection molding machine (IMM). The device (10) includes an actuator controller (16) that receives and uses one or more sensor signals in a program that: The actuator (5, 940, 941, 942) or its associated valve pin (1040, 1041, 1042) moves during the injection cycle to a position corresponding to a predetermined injection fluid pressure profile, a linear or rotary pin position, a linear actuator or valve pin position, a barrel screw position, or a position corresponding to the barrel pressure or actuator drive fluid pressure; or The actuator (940e, 941e, 942e, 940p, 941p, 942p) or its associated valve pin (1040, 1041, 1042) is instructed to retract from the upstream closed gate position at a deceleration along a selected stroke path upstream; or The actuator (940e, 941e, 942e, 940p, 941p, 942p) or its associated valve pin (1040, 1041, 1042) moves such that the valve pin is driven downstream at a decreasing speed along a selected stroke path, wherein the distal tip of the pin moves from upstream of the gate to the gate closed position; or The actuator (940e, 941e, 942e, 940p, 941p, 942p) or its associated valve pin (1040, 1041, 1042) is moved such that the valve pin is driven upstream or downstream to an intermediate position between a gate closed position and a fully upstream position, wherein the valve pin remains in the intermediate position for a selected period of time during the injection cycle, wherein, in the intermediate position, the distal tip of the valve pin restricts the injection flow of the injectable to be less than the maximum flow rate.

[0084] In this device, one or more valve pins (1040, 1041) have tips (1142, 1155), and one or more selected actuators (940, 941, 942) are controlled to move the relevant valve pin upstream along a stroke path between a downstream gate closed position (GC) and one or more intermediate upstream gate open positions (COP, COP2). The downstream gate closed position (GC) is the position where the tip of the valve pin (1142, 1155) blocks the gate (34, 36) to prevent fluid material from flowing into the mold cavity. The one or more intermediate upstream gate open positions (COP, COP2) are predetermined positions between the downstream gate closed position and the upstream stroke end position (EOS) of the intermediate upstream gate open position. The gate (34, 36) is in a partially open state when the valve pin (1040, 1041) is in one or more intermediate upstream gate open positions (COP, COP2), and the gate is in a more fully open state when the valve pin is in the stroke end position. The device includes: Position sensors (950, 951, 952) sense the position of the selected valve pin (1041) or the associated selected actuator (941); The controller (16) includes instructions to instruct the selected actuator (951) to drive the valve pin (1041): During the stroke of the valve pin through one or more intermediate upstream gate open positions, it travels upstream at one or more selected intermediate speeds in response to a signal received by the controller from the position sensor that the valve pin is set at one or more intermediate upstream gate open positions; During the upstream movement of the valve pin between one or more intermediate upstream gate open positions and stroke end (EOS) positions, it moves upstream at a higher upstream speed than one or more selected intermediate speeds.

[0085] Such a device may include: First and second actuators (940, 941) are interconnected with first and second valve pins (1040, 1041) having tips (1142, 1155), respectively. The second actuator (941) is instructed by the controller (16) to drive the second valve pin (1041) upstream along a stroke path (RP, RP2) between a downstream gate closed position (GC), one or more intermediate upstream gate open positions (COP, COP2) and a stroke end position (EOS), wherein fluid material (18, NM, 100b) flows through the gate at a selected maximum rate. The downstream gate closed position (GC) is the position where the tip of the valve pin blocks the gate (32, 34) to prevent fluid material from flowing into the mold cavity. One or more intermediate upstream gate open positions (COP, COP2) are predetermined positions between the downstream gate closed position (GC) and the stroke end position (EOS). In this embodiment, at least one position sensor (951) senses the position of the second valve pin (1041) or the second actuator (941); The controller (16) controls the movement of the second actuator (941) at least in part according to instructions, which instruct the second actuator (941): After the fluid material (100p) is injected through the first gate (32) and flows downstream through the cavity (30), the second gate (34) is opened; and During the movement of the second valve pin (1041), the second valve pin (1041) is driven upstream through one or more intermediate upstream gate opening positions (COP, COP2) at one or more selected intermediate speeds in response to a signal from the position sensor (951) indicating that the second valve pin (1041) is set at a selected intermediate upstream gate opening position; and The second valve pin (1041) is driven at a speed higher than one or more selected intermediate speeds in response to a signal from a position sensor (951) indicating that the second valve pin is set at a selected intermediate upstream gate open position (COP, COP2).

[0086] In such a device, the controller (16) typically includes instructions that instruct the second actuator (941) to open the second gate (34) after the fluid material (100p) injected through the first gate (32) flows downstream of the cavity (30) through the second gate (34).

[0087] In another aspect of the invention, a method for performing an injection molding cycle is provided, the method comprising operating any system or apparatus of claims 1-58 to perform the injection cycle.

[0088] Without any specific clarification regarding its express use in particular cases, when the terms “basically” or “about” in any grammatical form are used as modifiers (e.g., modifying structure, size, measurement, or some other feature) in this disclosure and any appended claims, it should be understood that the variation in that feature can be up to 30%. For example, an element may be described as substantially insulated or isolated from another element (such as a heating manifold) in thermal or heat communication. Or an element may be described as being substantially in thermal or heat communication with another element (such as a heating manifold). In these cases, the element described as being substantially in thermal communication will be arranged relative to the heating or heat-generating assembly (e.g., a heating manifold) such that heat can be easily conducted to the main element. Similarly, length, speed, or time may also be described in relation to a particular length, speed, or time. In these cases, using “about” to modify a feature allows for a variance in the feature of up to 30%. Thus, a path length described as being between about 1 and about 8 mm includes paths between 0.7 or 1.3 mm and 5.6 or 10.4 mm. Attached Figure Description

[0089] The accompanying drawings contain part numbers and device numbers corresponding to those appearing in the appended description of the invention.

[0090] Figure 1 This is a side view of an injection molding apparatus having a central valve gate with an associated actuator (940) and two downstream valve gates with associated actuators (941, 942). The downstream valve gates open into the mold cavity in a predetermined sequence after the central valve gate opens first. Each actuator (940, 941, 942) includes an electric motor with an electric driver (940d, 941d, 942d). The electric driver is contained in or physically mounted on the actuator housing (940h, 941h, 942h) such that the electric driver (940d, 941d, 942d) is in direct thermal communication with the actuator housing (940h, 941h, 942h). The housing of each actuator (940, 941, 942) is mounted on or physically close to the heating manifold or in direct thermal communication with the heating manifold.

[0091] Figure 1A This is a side view of an electric actuator (941) consisting of a housing (941h) and an electric actuator (941d), which can be easily connected to and removed from the housing (941h) of the actuator by a conventional connection and separation mechanism such as a bolt (941b).

[0092] Figure 2 It is similar to Figure 1 A side view of the electric actuator in the device, wherein the actuator (940) has a drive shaft Y arranged non-coaxially relative to the stroke axis of the valve pin (1040), and the actuator (940) is mounted on the linear stroke converter (940l, 940h), the actuator housing (940h) is mounted to the heating manifold or directly thermally connected to the heating manifold (40), and the linear stroke converter is mounted on the heating manifold or directly thermally connected to or in contact with the heating manifold (40).

[0093] Figure 2AThis is a top front perspective view of an embodiment consisting of an electric actuator (940) having a drive shaft Y arranged non-coaxially relative to the stroke axis of the valve pin (1040). The actuator housing (940h) and the electric drive (940d) are mounted on a rotary reduction device (46), which is mounted on or physically close to the heating manifold (40). The rotary reduction device is then mounted on a linear stroke converter (940l, 940h), which is then mounted on or physically close to the heating manifold (40). The heating manifold (40) has cooling devices (940mc, 940mc1, 940mc2, 941mc, 942mc) placed between the heating manifold (40), linear stroke converters (940l, 940h), rotary speed reducers (46), actuator housings (940h, 941h, 942h) and electric actuators (940d), and the cooling devices are adapted to substantially isolate or insulate at least the electric actuators (940d, 941d, 942d) from heat dissipated or emitted from the heating manifold (40).

[0094] Figure 2B yes Figure 2A A side cross-sectional view of the device obtained along line 2B-2B.

[0095] Figure 2BB It is a close-up cross-sectional view of the bracket or seat through which the linear converter 940l and its housing 940lh (together with the reduction gear 46 and the actuator 940, the converter 940l is assembled separately to the actuator 940) are rotated and mounted to the heating manifold (40).

[0096] Figure 2C yes Figure 2B , 2BB A cross-sectional perspective view of the top front portion of the component.

[0097] Figure 2D Is it like this? Figure 2A , 2B Side view of the rotary deceleration device 46 and the harmonic and rotary-to-linear converter device 940l assembly shown in 2BB and 2C.

[0098] Figure 2E for Figure 2A , 2B Exploded perspective view of the top rear of the deceleration device 46 shown in 2BB, 2C, and 2D.

[0099] Figure 2FThis is a top front perspective view of another embodiment, which includes an actuator having a drive shaft Y arranged non-coaxially relative to the stroke axis of a valve pin (1040), by mounting the actuator (940) onto a linear stroke converter (940l, 940lh) that rotates to, with the actuator housing (940h) mounted on or physically close to a heating manifold (40), the linear stroke converter being mounted on or physically close to the heating manifold (40) with cooling devices (940mc, 940mc1, 940mc2, 941mc, 942mc), the cooling devices being disposed between the heating manifold (40), the linear stroke converter (940l, 940h), the actuator housing (940h, 941h, 942h), and the electric actuator (940d), the cooling devices being adapted to substantially isolate or insulate at least the electric actuator (940d, 941d, 942d) from heat dissipated or emitted from the heating manifold (40).

[0100] Figure 2G for Figure 2F Cross-sectional view of the device along line 2G-2G.

[0101] Figure 2H This is a top front perspective view of another embodiment, which includes an actuator having a drive shaft Y arranged non-coaxially relative to the stroke axis of a valve pin (1040). The actuator (940) is mounted to a linear stroke converter (940l, 940h), with the actuator housing (940h) mounted on or physically close to a heating manifold (40). The linear stroke converter is instead mounted on or physically close to the heating manifold (40) with cooling devices (940mc, 940mc1, 940mc2, 941mc, 942mc). The cooling devices are disposed between the heating manifold (40), the linear stroke converter (940l, 940h), the actuator housing (940h, 941h, 942h), and the electric actuator (940d). The cooling devices are adapted to substantially isolate or insulate at least the electric actuator (940d, 941d, 942d) from the heat dissipated or emitted by the heating manifold (40).

[0102] Figure 2I It was obtained along the 2I-2I line. Figure 2H Cross-sectional view of the device.

[0103] Figure 3A It is similar to Figure 1A side view of the electric actuator in the device, wherein the actuator (940) has a drive shaft Y coaxial with the stroke axis of the valve pin (1040), the actuator housing (940h) is mounted on or physically close to the heating manifold (40), the heating manifold is equipped with cooling devices (940mc, 940mc1, 940mc2, 941mc, 942mc), the cooling devices are disposed between the heating manifold (40) and the actuator housing (940h, 941h, 942h) and the electric actuator (940d), the cooling devices being adapted to substantially isolate or insulate at least the electric actuator (940d, 941d, 942d) from the heat dissipated or emitted from the heating manifold (40).

[0104] Figure 3B It is similar to Figure 1 A side view of the electric actuator in the device, wherein the actuator (940) has a drive shaft Y coaxial with the stroke shaft of the valve pin (1040), and the actuator housing (940h) is mounted on the heating manifold (40) or directly in thermal communication or contact with the heating manifold (40) via a seat (940s) mounted on the heating manifold (40) or mounted to the heating manifold (40) or directly in thermal communication or contact with the heating manifold (40).

[0105] Figure 4 Is with Figure 1 , 2 A side view of another electric actuator in a similar device, wherein the actuator (940) has a drive shaft Y arranged non-coaxially with respect to the stroke axis of the valve pin (1040), the actuator housing (940h) is mounted to the top clamp (80) in one iteration (940), and the linear stroke converter is mounted to the heating manifold (40) or in direct thermal communication or contact with it by mounting the actuator (940) to the linear stroke converter (940, 940h). In another iteration (940a), the actuator housing may or may not be mounted to the top clamp 80.

[0106] Figure 4A An alternative embodiment is provided in which the rotary-to-linear stroke converter 120 is interconnected with an actuator for converting rotary motion into linear motion along a non-coaxial axis relative to the rotor axis, and wherein a cooling channel 125 is disposed within a housing 120ro, which is readily connected to and detachable from the main linear converter housing 120ri.

[0107] Figure 5 It is similar to Figure 1 , 2A side view of another electric actuator in the device, wherein the actuator (940) has a drive shaft Y arranged non-coaxially with respect to the stroke axis of the valve pin (1040), by mounting the actuator (940) onto the linear stroke converter (940l, 940h), the actuator housing (940h) being mounted to or in direct thermal communication with the heating manifold (40), the linear stroke converter being mounted on or to the top clamp (80), and the linear stroke converter being configured to be in direct thermal communication with the heating manifold (40).

[0108] Figure 6 It is similar to Figure 1 The top left rear perspective view of the system's injection molding system shows a specific configuration of the distal housing cooling assembly with a specific configuration of active cooling channels incorporated into the body of the assembly.

[0109] Figure 6A It is along line 6A-6A Figure 6 The system's cross-sectional end view shows details of the remote cooling housing assembly.

[0110] Figure 6B yes Figure 6 A side view of the injection molding system, showing details of the rotor and driver, stator and armature, components, and how they are mounted within the actuator housing.

[0111] Figure 7 This is a top left rear view of an injection molding system. The injection molding system has a housing cooling assembly that is positioned and extends along the bottom radial wall of the housing, and has active cooling channels within the radial wall.

[0112] Figure 7A It is along Figure 7 Line 7A-7A Figure 7 Side cross-sectional view of the system.

[0113] Figure 8 This is a top left rear view of an injection molding system. The injection molding system has a housing cooling assembly that is arranged and extends along a pair of opposite side radial walls of the actuator housing, and active cooling channels are provided in the side radial walls.

[0114] Figure 8A It is along Figure 8 The cross-sectional view of line 8A-8A.

[0115] Figure 9 This is a top rear perspective view of an injection molding system with an actuator housing wall, which consists of a non-actively cooled top radial plate member and a single housing member consisting of actively cooled axial and lateral radial walls.

[0116] Figure 10 yes Figure 9 End view of the device.

[0117] Figure 11 yes Figure 9 Exploded perspective view of the system.

[0118] Figure 12 This is a front right perspective view of an injection molding system, showing an electric motor actuator mounted on a linear-to-linear converter 15. The linear converter has a converter housing 120 with opposing left and right radial sidewalls containing actively cooled cooling channels. The sidewalls are assembled with non-actively cooled upper and lower axial wall panels.

[0119] Figure 12A It is along Figure 12 The cross-sectional view obtained from line 12A.

[0120] Figures 13A-13E yes Figure 1 A schematic cross-sectional close-up view of the center of the device and one of the side gates 34 shows the various stages of the sequential injection process.

[0121] Figures 14A-14B The position of the conical end valve pin at different times is shown, and Figure 14A The position shown is between the initial closed position and various upstream open positions. RP represents a path of selectable length on which the speed at which the pin exits upstream from the gate closed position to the open position decreases relative to the upstream movement speed of the valve pin on the uncontrolled speed path FOV when the pin speed is at its maximum value.

[0122] Figures 15A-15B A device with a valve pin is shown, the valve pin having a cylindrically configured tip, the tip of the pin being located at... Figure 15A The different times and positions shown are between the initial closed position and the upstream open position, RP, where RP represents a path of selectable length on which the speed at which the pin exits from the gate closed position upstream to the open position is reduced relative to the upstream movement speed that the valve pin typically has on the uncontrolled speed path FOV when the pin speed reaches its maximum value.

[0123] Figure 16This is a side schematic view of another embodiment of an injection molding system, which includes an electric actuator with an electric driver 940d mounted on or to the actuator housing. The actuator and electric driver 940d are mounted in an extended spacing relationship relative to the heating manifold 40, such that the actuator and electric driver 940d are substantially or significantly thermally isolated or isolated from the heating manifold 40. In the illustrated embodiment, the actuator and electric driver are mounted on a cold or cooled top clamp 140 and interconnected with a rotation-to-linear drive conversion device, which is also mounted on the top clamp.

[0124] Figure 17 is a side schematic view of a prior art injection molding apparatus, wherein the injection molding machine (IMM) includes a stock or standard IMM controller or signal generator that sends a standard IMM controller signal to a solenoid valve of a directional flow control valve, the solenoid valve indicating that the position of the valve gate moves between a valve gate closed position and a valve gate open position.

[0125] Figure 18 This is a side schematic view of an embodiment of an injection molding apparatus according to the present invention, wherein the valve gate includes an electrically powered or electric motor, the apparatus includes a machine signal converter that receives a standard signal generated by an injection molding machine controller, converts the signal into a control signal compatible with the signal receptor of the electric actuator used in the apparatus, and routes the converted signal to the actuator processor.

[0126] Figure 19 It is a general schematic diagram of the signal communication arrangement between the interfaces of the injection molding machine controller, sensor, signal converter and electric actuator or proportional directional control valve.

[0127] Figure 20 This is a schematic diagram of the signal communication arrangement between the injection molding machine controller, position sensor, signal converter, and electric actuator.

[0128] Figure 21 This is a schematic side view of the armature and drive rod assembly of a linearly driven proportional solenoid, which can replace the assembly of the rotary motion enabling assembly of the rotary electric actuator described herein, to enable direct linear drive motion of the drive rod via the armature when energized.

[0129] Figure 22 This is a schematic side view of the armature and drive rod assembly of a linear motor, which can replace the assembly of the rotary motion enabling component of the rotary electric actuator described herein, to enable direct linear drive motion of the drive rod via the armature when energized. Detailed Implementation

[0130] Figure 1An injection molding apparatus is shown, comprising a central valve with associated actuators (940) and two downstream valves with associated actuators (941, 942). The downstream valves open into a mold cavity 30 in a predetermined sequence as described herein after the central valve opens first. Each actuator (940, 941, 942) includes an electric motor with an electric actuator (940d, 941d, 942d). The electric actuators (940d, 941d, 942d) may be mounted within the same housing (940h, 941h, 942h) as the drive components of the electric actuators (940, 941, 941), or the electric actuators (940d, 941d, 942d) may be mounted within a physically separate thermally conductive housing (941d), such as... Figure 1A As shown, the heat-conducting housing is easily attached to or removed from the housing (941h), which (941h) houses the drive assembly (stator, armature) and rotor assembly (941b) of the electric actuator using conventional means such as bolts, screws, clips, and magnets. Figure 1A As shown, the heat-conducting housing (941ds) is connected to the heating manifold (40) through the heat-conducting installation of the heat-conducting housing (941ds) to the actuator housing (940h), and the actuator housing (940h) is connected to the heating manifold (40) through the mounting device (940mm) for basic heat conduction or thermal conduction.

[0131] like Figure 1 As shown, the housing of the actuators (940h, 941h, 942h) may have cooling channels 25 embedded within the housings 940h and 941h, similar to... Figure 8 , 8A In some embodiments, or as described herein, easily removable and connectable housing components, such as assembly 20ao, which includes the active cooling channel 25 described herein, can be connected to housings 940h, 941h, 942h. This active cooling channel is typically interconnected with a source 260 of cooling fluid 25f, which is pumped through channel 25 to cool actuator housings 940h, 941h, 942h and their associated mounted or embedded components, including electric actuators 940d, 941d, 942d and actuators 100, 200.

[0132] like Figure 1AAs shown, active cooling channels 25 can be alternately provided or disposed within the main body of the actuator housings 940ds, 941ds, 942ds housing electric actuators 940d, 941d, 942d. Such actuator housings can be easily connected to and removed from the actuator housings 940h, 941h, 942h. These active cooling channels 25 are typically connected to a source 260 of cooling fluid 25f, which is pumped through channels 25 to cool the actuator housings 940h, 941h, 942h and their associated mounted or embedded components, including electric actuators 940d, 941d, 942d and actuators 100, 200.

[0133] Similarly, it has a linear drive member 940l ( Figure 4 , 12 The rotation to linear stroke converter 15 is interconnected with actuator housings 20, 940. The linear stroke converter housings 940lh, 120ro may include a cooling channel 25, which is interconnected with a source 260 of cooling fluid 25f. The cooling fluid 25f is pumped through the channel 25 to cool the actuator housings 940h, 941h, 942h and their associated mounting or embedded components, including electric actuators 940d, 941d, 942d and actuators 100, 200.

[0134] In such Figure 4A In the alternative embodiment shown, cooling channel 125 may be disposed within housing assembly 120ro, which is readily attachable to and detachable from the main linear converter housings 940lh, 120ri. In such an embodiment, cooling fluid 125f can be pumped through channel 125 to cool the linear converter housings 120ro, 120ri and actuator housings 940h, 941h, 942h and their associated mounting or embedded components, including electric actuators 940d, 941d, 942d and actuators 100, 200.

[0135] like Figure 1 , 1A As shown in all embodiments 2, 3, 4, and 5, the electric actuators (940d, 941d, 942d) are mounted on or to the actuator housing (940h, 941h, 942h) in such a way that the drive elements (such as pulse width modulators (PWM)) and associated electrical components are configured to be substantially thermally connected to or in contact with the actuator housing (940h, 941h, 942h) or the heating manifold (40).

[0136] like Figure 1 , 13AAs shown in -13E, the injection cycle can be a cascaded process, wherein the injection sequence begins with injection from the central nozzle 22, followed by injection from the side nozzles 20 and 24 at predetermined times. Figure 13A As shown, the injection cycle first opens the pin 1040 of the central nozzle 22, allowing the fluid material 100 (typically a polymer or plastic material) to flow upward into the cavity at position 100a, and then enters the cavities 34, 36 of the gating gates of the side nozzles 24, 20 just before the inlet located at the distal end of 100b. Figure 1 As shown. After the injection cycle begins, the gate of the center injection nozzle 22 and pin 1040 is typically only opened for a short period to allow the fluid material 100b to move just past positions 34, 36 to position 100p. Once the fluid material has just flowed past 100p of the side gate positions 34, 36, the center gate 32 of the center nozzle 22 is typically closed by pin 1040, as shown. Figure 13B , 13C As shown in 13D and 13E. Figure 13B-13E As shown, side gates 34 and 36 are opened by exiting the upstream side gate pins 1041 and 1042. The upstream exit rate or stroke speed of the side pins 1041 and 1042 can be controlled as follows.

[0137] In an alternative embodiment, the center gate 32 and the associated actuator 940 and valve pin 1040 may remain open at the time, during and after the side gates 34, 36 are opened, so that fluid material flows into the cavity 30 simultaneously through one or both of the center gate 32 and the side gates 34, 36.

[0138] When side gates 34 and 36 are opened, allowing the fluid material NM to first enter the mold cavity and flow 102p injected from the center nozzle 22 through gates 34 and 36, the two flows NM and 102p mix. If the velocity of the fluid material NM is too high, as often happens when the injection velocity of the fluid material through gates 34 and 36 reaches its maximum, noticeable lines or defects from the mixing of the two flows 102p and NM will appear in the area of ​​the mold cavity injected through gates 34 and 36. By injecting NM at a lower velocity for a relatively short time when gates 34 and 36 are first opened, and then after NM first enters the flow stream 102p, the appearance of visible lines or defects in the final molded product can be reduced or eliminated.

[0139] The controller 16 controls the rate or speed at which the electric actuators 940, 941, and 942 begin to exit from the closed position by controlling the speed and direction of their drive.

[0140] The user programs the controller 16 via data input on the user interface to instruct the electric actuator to drive pins 1041 and 1042 at a reduced upstream speed relative to the maximum speed at which the actuator can drive pins 1041 and 1042. This reduced pin exit rate or speed is executed until position sensors (such as 951 and 952) detect that the actuators 941 and 952 or the associated valve pins (or other components) have reached a position, such as the endpoints COP and COP2 of the restricted flow channels RP and RP2. Figure 14B , 15B The typical time for withdrawing the pin at a decelerating rate is between 0.01 and 0.10 seconds, and the total injection cycle time is usually between 0.3 and 3 seconds, more commonly between 0.5 and 1.5 seconds.

[0141] Figure 1 Position sensors 950, 951, and 952 are shown, used to sense the positions of motors 940, 941, and 942 and their associated valve pins (such as 1040, 1041, and 1042), and feed this position information to controller 16 for monitoring. As shown, fluid material 18 is injected from the injection molding machine into manifold channel 19, and further downstream into orifices 44 and 46 of side nozzles 24 and 22, and finally downstream through gates 32, 34, and 36. Figure 13D As shown, the flow rate of fluid material through gates 34 and 36 is maximum when pins 1041 and 1042 are withdrawn upstream to the position where the tip of pin 1041 is in the fully upstream open position. However, when pins 1041 and 1042 are initially withdrawn from the closed gate position ( Figure 13A ) began to exit to the middle upstream position ( Figure 13B , 13C When the pins 44 and 46 are closed, gaps 1154 and 1156 are formed between the outer surface 1155 of the tips and the inner surfaces 1254 and 1256 of the gate areas of nozzles 24 and 20 to restrict the flow velocity of the fluid material. The restricted flow gaps 1154 and 1156 are kept sufficiently small to limit and reduce the flow velocity of the fluid material 1153 through the gates 34 and 36, making it less than the maximum flow velocity of the tips of pins 1041 and 1042 over the travel distance RP from the closed end to the upstream end. Figure 1 , 13B As shown in 13C, 13E and 14B, 15B.

[0142] Pin 1041 can be controllably withdrawn over the entire length of path RP at one or more reduced speeds (less than the maximum speed) for one or more time periods, restricting the flow of molding material 1153 along path RP. Preferably, the pin withdraws at a reduced speed over approximately 50% of the length of RP, and most preferably, over approximately 75% of the length of RP. See the figure below for reference. Figure 14B , 15BPin 1041 can exit at a higher or maximum speed at the end of the incomplete, restricted molding material flow path RP2, COP2.

[0143] By reducing or controlling the speed at which pins 1041 and 1042 open or exit upstream from the gate closed position to a selected intermediate upstream gate open position (preferably 75% or more of the RP length), traces or visible lines that appear in the final part body formed within the mold cavity can be reduced or eliminated.

[0144] The RP length is approximately 1-8 mm, more typically 2-6 mm, even more typically 2-4 mm, and still more typically 1-5 mm. According to the invention, the position of the electric actuator is adjusted to less than 100% open based on the position sensing of suitable components such as the rotors of actuators 941, 942 or associated valve pins. The drives of actuators 931, 942 are adjusted to reduce the upstream movement speed of pins 1041, 1042 during a selected time period. At the end of the stroke or length of path RP, RP2, the position sensor sends a signal to the controller 16, which determines that the end COP, COP2 has been reached and drives the valve pins at a higher speed, typically to the end of its stroke (EOS) or its 100% open position, to allow the actuator piston and valve pins 1041, 1042 to be driven at maximum upstream speed FOV to reduce the cycle time of the injection cycle.

[0145] Typically, the user selects one or more reduced speeds, which are less than approximately 90% of the maximum speed (i.e., the speed when the valve gate is fully open at 600°), more typically less than approximately 75% of the maximum speed, and even more typically less than approximately 50% of the maximum speed, where pins 1041 and 1042 are driven by electric actuators. The actual maximum speed of the actuators 941 and 942 and their associated pins 1041 and 1042 is predetermined by selecting the size and configuration of the actuators 941 and 942. The maximum drive rate of the electric actuators is predetermined by the equipment manufacturer and the user, typically selected based on the mold and the application, size, and nature of the injection-molded part to be manufactured.

[0146] Preferably, the valve pin and the gate are configured or adapted to cooperate with each other to restrict and alter the movement of the liquid material 1153 during the passage of the tip of the valve pin through the restricted velocity path RP. Figures 14A-14B , Figures 15A-15B The flow rate. The most common example is... Figure 14A , 14B As shown, the radial tip end face 1155 of the ends 1142 of pins 1041 and 1042 is conical or tapered, and the pin surface 1155 is intended to be complementary to the surface of the gate 1254 that mates with it to close the gate 34 in a conical or tapered structure. Alternatively, as Figure 15A , 15BAs shown, the radial surface 1155 of the tip 1142 of pins 1041 and 1042 may be cylindrical, and the gate may have a complementary cylindrical surface 1254. When pin 1041 is in the downstream gate closed position, the tip 1155 engages with the gate 1254 to close the gate 34. In any embodiment, the outer radial surface 1155 of the end 1142 of pin 1041 passes through and creates a restricted flow channel 1154 along the travel length of the end 1142 of pin 1041. When the tip 1142 of pin 1041 moves to or beyond the length of the restricted flow channel RP, the restricted flow channel RP restricts or reduces the volume or velocity of the fluid material 1153 relative to pins 1041 and 1042 when they are in the fully gate open position.

[0147] In one embodiment, because the tip 1142 of pin 1041 continues from the GC position where the gate is closed (e.g., as Figure 14A , 15A As shown, the material flow 1153 travels upwards along the length of the RP path (i.e., the path traveled within a predetermined amount of time). The rate at which the material flow 1153 enters the cavity 30 through the gate 34 via the limiting gap 1154 continues to increase from 0 at the gate-closed GC position until the pin tip 1142 reaches the position FOP (fully open), at which point the pin no longer restricts the injection-molded material from passing through the gate. In such an embodiment, when the predetermined time for the pin tip 1142 to reach the FOP (fully open) position expires, the pin 1041 is immediately driven at its maximum speed FOV (fully open velocity). In an alternative embodiment, when the predetermined time for driving the pin at a reduced speed has expired and the tip 1142 has reached the end of the restricted flow channel RP2, the tip 1142 may not necessarily be located at the position where the liquid flow 1153 is no longer restricted. In such an alternative embodiment, when the pin reaches the transition position COP2, the liquid flow 1153 can still be restricted to less than the maximum flow rate, where the pin 1041 is driven at a higher, typically maximum, upstream speed FOV.

[0148] exist Figure 14B , 15B In the alternative example shown, when the pin moves the predetermined path length at a decreasing speed and the tip 1142 reaches the transition point COP, the tip 1142 of the pin 1041 (and its radial surface 1155) no longer restricts the flow rate of the fluid material 1153 through the gap 1154, because the gap 1154 has been increased to a size that no longer restricts the liquid flow 1153 below the maximum flow rate of the material 1153. Therefore, in Figure 14B In one example shown, the maximum liquid flow rate of the injected material 1153 is reached at the COP location upstream of the tip 1142. Figure 14B , 15BIn another example shown, pin 1041 can be driven at a reduced speed on a shorter path RP2 that is less than the entire length of the restricted mold material flow path RP, and switch to a higher or maximum speed FOV at the end COP2 of the shorter restricted path RP2. In another alternative embodiment, pin 1041 can be driven and instructed to be driven at a reduced or less than maximum speed on a longer path length RP3 with an upstream portion UR, wherein the flow of injection fluid mold material is unrestricted and flows at a maximum rate through the gate 34 for a given injection molding apparatus. In this example, the speed or drive rate of pin 1041 does not change until the tip of pin 1041 or actuator 941 reaches the switching position COP3. As in other embodiments, a position sensor senses that valve pin 1041 or associated components have traveled path length RP3 or reached the end COP3 of the selected path length, and the controller receives and processes this information and instructs the drive to drive pin 1041 at a higher, typically maximum, upstream speed. In another alternative embodiment, during the injection cycle from the gate-closed position GC to the stroke-end position EOS, pin 1041 can be driven at a reduced or less than maximum speed throughout the entire stroke path of the pin, and controller 16 is programmed to instruct the drive system of the driver to drive the actuator at one or more reduced speeds throughout the time or path length of the entire cycle from GC-closed to EOS-fully-opened.

[0149] Typically, when the time period for driving pin 1041 at a reduced speed has expired, and the tip 1142 of the pin reaches positions COP and COP2, pins 1041 and 1042 are driven at the maximum speed or stroke rate at which the actuator system can drive valve pins 1041 and 1042. Alternatively, pins 1041 and 1042 can be driven at a preselected FOV speed less than the maximum speed, at which the pin can be driven when the limit valve 600 is fully open, but still greater than the reduced speed selected for the pin during its journey from the RP and RP2 paths to the COP and COP2 positions.

[0150] At the end of the predetermined reduced speed drive time, pins 1041 and 1042 are typically driven upstream, past positions COP and COP2, to the maximum stroke end EOS position. The stroke end position EOS is the user-selected upstream position, which can be either the maximum upstream position to which the pin can retract or a position less than the maximum upstream position to which the valve pin can retract. The upstream COP and COP2 positions are located downstream of the maximum upstream stroke end EOS opening position of pin tip 1042. The length of path RP or RP2 is typically between approximately 2 and approximately 8 mm, more typically between approximately 2 and approximately 6 mm, and most typically between approximately 2 and approximately 4 mm. In practice, the maximum upstream (stroke end) opening position EOS of pins 1041 and 1042 ranges from approximately 8 mm to approximately 18 inches upstream of the gate GC position.

[0151] As shown in each embodiment, the electric actuators (940d, 941d, 942d) are incorporated into, physically mounted on, or directly thermally connected to the actuator housings (940h, 941h, 942h), such that the electric actuators (940d, 941d, 942d) are directly thermally connected to or in contact with the thermally conductive housings (940h, 941h, 942h) of the actuator.

[0152] The electric actuators (940d, 941d, 942d) can be housed or mounted in a heat-conducting housing (940ds), which is easily connected to or removed from the actuator housing (940h, 941h, 942h), such as... Figure 1 , 1A As shown in Figures 3 and 6, this easily connectable and detachable outer housing (940ds) is easily connected or installed onto and detached from the actuator housing (940h, 941h, 942h) in an arrangement, allowing the electric actuator (940d, 941d, 942d) to have direct thermal contact or communication with the actuator housing (940h, 941h, 942h).

[0153] like Figure 1-12A As shown, the housing (940h, 944h, 942h) of each actuator (5, 940, 941, 942) is mounted or physically close to or in direct thermal communication with the heating manifold (40, 300).

[0154] Electric actuators 940, 941, and 942 typically include drivers 940dr, 941dr, and 942dr, which typically include a stator and an armature, interconnected with rotatably mounted rotors or shafts 940r, 941r, and 942r, such that when drivers 940dr, 941dr, and 942dr rotate due to the application and receipt of electrical energy or power, shafts 940r, 941r, and 942r rotate simultaneously and are driven. The rotors (940r, 941r, 942r) have a drive shaft (Y). Figure 1 etc. The drivers (940dr, 941dr, 942dr) are interconnected with the rotors (940r, 941r, 942r) and are adapted to controllably drive the rotors to rotate around the drive shaft Y.

[0155] The actuators (940dr, 941dr, 942dr) receive electrical energy or power from the electric actuators (940d, 941d, 942d). The electric actuators (940d, 941d, 942d) typically include an interface that receives electrical energy or power from the power supply PS and controllably distributes the received electrical energy or power to the actuators (940dr, 941dr, 942dr) in a controllable and varying amount during the injection cycle.

[0156] Actuators 5, 940, 941, and 942 include housings (940h, 941h, and 942h) that house rotors (940r, 941r, and 942r) and actuators (940dr, 941dr, and 942dr) and are adapted to support the rotors (940r, 941r, and 942r) so that the rotors can be driven to rotate 940rt, 941rt, and 942rt. The housings (940h, 941h, and 942h) are generally thermally conductive or heat-conducting, allowing the housings to receive heat or thermal energy from devices such as manifolds (40), and the housings (940h, 941h, and 942h) can be in thermal communication or contact with the manifolds (40).

[0157] The electric actuators (940d, 941d, 942d) are typically housed within or by a housing (940h, 941h, 942h), or physically mounted on or in contact with the housing (940h, 941h, 942h) and are in thermal communication with or in contact with the housing.

[0158] The housings (940h, 941h, 942h) are typically installed in physical proximity or configuration relative to the heating manifolds (40, 300), or in direct or indirect thermal contact with the heating manifolds (40, 300), such that one or the other or both of the housings (940h, 941h, 942h) and the electric actuators (940d, 941d, 942d) are in a substantially thermal or thermally connected or contacted state with the heating manifolds (40).

[0159] The electric actuators (940d, 941d, 942d) typically include PWM or pulse width modulators that convert received electrical energy or power into sinusoidal voltage waveforms, each of which is suitable for driving the corresponding phase coil of the actuator driver (940dr, 941dr, 942dr).

[0160] A PWM or pulse width modulator typically includes an inverter or a comparator.

[0161] A PWM modulator typically includes a three-phase PWM inverter that converts electrical energy or power received from the interface into three sinusoidal voltage waveforms, each of which is adapted to drive a corresponding one of the three phase coils of the actuator driver.

[0162] The electrical energy or power received at or by the PWM modulator can be the DC bus voltage.

[0163] The interfaces of the electric drivers 940d, 941d, and 942d are adapted to receive one or more control signals from the controller 16 of the injection molding apparatus, and to convert the electrical energy or power received by the power supply PS into a sinusoidal waveform according to the one or more control signals. The interface consists of a PWM or pulse width modulator, which converts the electrical energy or power received from the power supply into a sinusoidal waveform according to one or more control signals.

[0164] The interface of the electric actuator receives one or more control signals containing control information that causes the pulse width modulator to convert the received electrical energy or power into a sinusoidal waveform suitable for driving the corresponding phase coil of the actuator driver, so as to adjust one or more positions, speeds or torques of the actuator rotors 940r, 941r, and 942r.

[0165] One or more control signals may include analog electrical signals received from controller 16 at the electric drive.

[0166] The electric drives 940d, 941d, and 942d may also include one or both of a digital signal receiving (16r) and transmitting (16s) device, such as... Figure 1A , 12 As shown. The controller (16) includes a digital command or signal generating mechanism, such as a computer driver, microcontroller, microcircuit, chipset, or the like, which is interconnected with and exchanges digital signals, data, or commands with a digital data storage medium. The controller (16) is adapted to send digital signals, commands, and data to a digital signal receiving device (16r) contained within an electric driver (940d, 941d, 942d). The digital commands (16s) received by the electric driver (940d, 941d, 942d) are used by the driver (940d, 941d, 942d) to control the distribution of electrical energy or power to the driver (940dr, 941dr, 942dr), thereby controlling the rotational speed of the actuator (940, 941, 942) rotor during the injection cycle.

[0167] The electric drive (940d, 941d, 942d) may also include a digital signal, data or command transmitting device (16s), which is typically composed of a microcontroller, microcircuit, chipset, etc., and is suitable for communicating with or transmitting digital signals to a digital signal receiving device contained in the controller (16).

[0168] Digital control signals may include one or more of the following: differential position command, differential current command, and differential speed command.

[0169] The digital signal receiving and transmitting devices (16r, 16s) can also receive digital signals from the actuator, wherein the digital signals received from the actuator include one or more feedback signals corresponding to one or more operations of the actuator and the actuator rotor.

[0170] The electric drive (940d, 941d, 942d) may receive one or more feedback signals from the actuator, including one or more incremental feedback signals and absolute feedback signals. Such incremental or absolute feedback signals sent by the actuator to the electric drive may be communicated via a digital signal transmitting device (16s) or sent back to the controller (16).

[0171] Figure 2 It showed something similar to Figure 1 In one embodiment of the device, the actuator (940) has a drive shaft Y arranged non-coaxially relative to the stroke axis of the valve pin (1040). By mounting the actuator (940) onto the linear stroke converter (940l, 940h), the actuator housing (940h) is mounted onto or in direct thermal communication with the heating manifold (40), and the linear stroke converter is mounted onto or in direct thermal communication with or in contact with the heating manifold (40).

[0172] Figures 2A to 2E An embodiment is shown in which the electric actuator (940) has a drive shaft Y arranged non-coaxially relative to the stroke axis of the valve pin (1040). By mounting the actuator (940) to a rotary reduction device (46), the actuator housing (940h) and the electric drive (940d) are mounted on or physically close to the heating manifold (40). The rotary reduction device is then mounted to a rotary-to-linear stroke converter (940l, 940h), which is then mounted on or close to or physically close to the heating manifold (40) with cooling devices (940mc, 940mc1, 940mc2, 941mc, 942mc). The cooling devices are disposed between the heating manifold (40), the rotary-to-linear stroke converter (940l, 940h), the reduction device (46), the actuator housing (940h, 941h, 942h), and the electric drive (940d). The cooling equipment is adapted to substantially isolate or insulate at least the electric actuators (940d, 941d, 942d) from the heat dissipated or emitted by the heating manifold (40). The cooling equipment is also generally adapted and arranged to insulate or insulate the actuator housing (940h), the rotary-to-linear converter (940l), and the reduction gear (46) from the heat dissipated or emitted by the heating manifold (40).

[0173] In this embodiment, the linear converter 940l and its housing 940lh are rotated together with the reduction gear 46 and the actuator 940, and the converter 940l is assembled on it and mounted on the heating manifold (40) by a bracket or seat 60, which is preferably made of heat-insulating materials such as titanium, bismuth, stainless steel, lead, chromium, etc.

[0174] In alternative implementations, such as Figure 2B The seat 60 of the seat 60s shown may be made of a highly thermally conductive material such as copper, which makes it easier for heat to be conducted from the actuator housing 940h to the active cooling seat 940mc.

[0175] Examples of direct metal-to-metal contact include Figure 2B As shown in the embodiment, the actuator housing 940h is in direct metal-to-metal contact with the heating manifold 40 via a seat 60, typically made of thermally insulating material. The actuator housing 940h is mounted in a seat 60s, which is also in direct metal-to-metal contact and is typically made of thermally conductive material. This seat 60 is mounted in direct metal-to-metal contact with the active cooling mount 940mc, allowing heat to be conducted from the actuator housing 940h to the active cooling mount 940mc, which acts as a radiator for the heat contained within the actuator housing 940h. The active cooling mount 940mc itself is mounted to the heating manifold 40 via direct metal-to-metal contact or communication with the seat 60, which in turn is mounted in direct metal-to-metal contact with the heating manifold 40. Therefore, the direct metal-to-metal contact of the seats 60 and 60s essentially achieves direct metal-to-metal communication or contact between the actuator housing 940h and the electric actuator 940d and the heating manifold 40.

[0176] like Figure 2D As shown, the reduction device 46 includes a harmonic device, and the rotation to the linear converter device 940l includes a wheel or disc that uses an eccentric or eccentrically configured pin or protrusion to drive the valve pin along the pin axis X.

[0177] exist Figures 2A to 2E In one embodiment, the conversion of motor motion is to directly convert the rotational motion of the rotor into the non-coaxial linear motion of the drive component 940l along the X-axis of the valve pin.

[0178] Figure 2F , 2GAnother embodiment is shown, which includes an actuator having a drive shaft Y arranged non-coaxially relative to the stroke axis of the valve pin (1040). The actuator (940) is mounted on a linear stroke converter (940l, 940lh) that rotates to it, with the actuator housing (940h) mounted on or physically close to the heating manifold (40). The linear stroke converter is, in turn, mounted on or physically close to the heating manifold (40) having cooling devices (940mc, 940mc1, 940mc2, 941mc, 942mc), the cooling devices being disposed between the heating manifold (40), the linear stroke converter (940l, 940h), the actuator housing (940h, 941h, 942h), and the electric actuator (940d). The cooling equipment is adapted and arranged to substantially isolate or insulate the electric actuators (940d, 941d, 942d) from the heat dissipated or emitted by the heating manifold (40). For example... Figure 2F , 2G As shown, the cooling device (940mc) comprises a single elongated plate on which the actuator housing (940h), electric drive (940d), converter (940l) and converter housing (940lh) are mounted. The cooling device is adapted and arranged to isolate or insulate all heat dissipated or emitted by the heating manifold (40) from the electric drive (940d), actuator housing (940h) and rotating to the linear converter (940l).

[0179] Figure 2HAnother embodiment is shown, which includes an actuator having a drive shaft Y arranged non-coaxially relative to the stroke axis of the valve pin (1040). The actuator (940) is mounted on a linear stroke converter (940l, 940h). The actuator housing (940h) is mounted on or physically close to a heating manifold (40), which in turn is mounted on or physically close to the heating manifold (40) with a separate unit cooling device (such as a plate (940mc1)) disposed between the heating manifold (40) and the linear stroke converter (940l, 940h). The actuator housing (940h) is mounted separately or mounted to a separate unit cooling device (940mc2). The cooling devices (940mc1, 940mc2) are each adapted and arranged to substantially isolate or insulate the electric actuators (940d, 941d, 942d) from heat dissipated or emitted from the heating manifold (40). As shown, the linear-to-linear converter (15) is mounted on a separate cooling device (940mc1) in the arrangement, such that the linear-to-linear converter (940l) and the electric actuator (940d) are substantially isolated or cut off from the basic communication of heat dissipated or emitted from the heating manifold (40). Also, as shown, the actuator housing (940h) is mounted on a separate cooling device (940mc2) in the arrangement, such that the actuator housing (940h) and the electric actuator (940d) are substantially isolated or cut off from the basic communication of heat dissipated or emitted from the heating manifold (40). As shown, each separate cooling device or plate (940mc1, 940mc2) individually includes a fluid channel (33) for receiving cooling or cooling fluid from the cooling device. Figure 2F , 2GIn embodiments 2H and 2I, the linear-to-linear converter 940l includes a stroke converter consisting of a slide body 507 fixedly connected to the linear drive shaft 150 of the actuator. The lower surface of the slide body 507 is slidably mounted on a mounting surface of the bottom wall of the sub-assembly housing, such that the slide body 507 is controllably driven along a first linear drive axis (Y) by a controlled drive of the actuator with controller 16. As shown in the specific embodiments, the slide body 507 is formed to include an aperture or slot within the slide body 507, the aperture or slot being configured and adapted to drive the valve pin 1040 relative to the drive of the actuator 940 at one or more selected speeds along the X-axis. The upstream end of the valve pin is fixedly connected to a driven pin, around which one or more wheels are typically mounted, typically rotatably mounted on the driven pin, as disclosed in WO2018 / 194961, the disclosure of which is fully incorporated herein by reference as if fully illustrated. The assembly of the housing, driven pin, valve pin, and manifold allows the guide groove to receive the driven pin and wheel in the arrangement, wherein the outer surface of the wheel engages the guide surface of the guide groove. When the slider 507 moves along the Y-axis, the groove moves along the X-axis, and the driven pin is forced to move along the non-coaxial X-axis by engaging with the moving groove surface; therefore, the valve pin moves along the X-axis together with the movement of the slider 507 along the Y-axis. The movement speed of the valve pin 1040 depends both on the profile or shape of the guide groove surface and on the movement speed of the linear drive member 150 of the actuator 940. Typically, Figure 2F , 2G In embodiment 2H, the linear drive member 150 is linearly driven along the Y-axis, and... Figure 3A , 3B In the embodiment, the linear drive member 940l is driven along the coaxial pin axis X via a rotor nut 940 having a thread 940rt, which can rotatably engage with the external thread 940lt of the drive member 940l. Similarly, Figure 2F , 2G The linear drive member 150 of the embodiment may include a nut (not shown) fixedly disposed on the distal end of the linear drive member 150, which, in the arrangement, is rotatably engaged with a complementary external thread 940rt disposed on the distal end of the motor rotor 940r, causing the drive member 150 to be reciprocated along a linear axis Y that is not coaxial with the linear pin axis X. In all cases, the linear drive members 150, 940, 940ld are linearly driven along selected X, Y axes and are arranged to reciprocate along the valve pin X axis to interconnect valve pins 1040, 1041. Figures 2F to 2IIn some embodiments, the groove has a linear or linear structure, such that the movement speed of the valve pin 1040 varies directly or linearly with the movement speed of the linear drive member 150. Alternatively, the groove 509 may have a stepped or curved structure, comprising two separate linear steps with different slopes or angles relative to the linear motion axis X, the steps causing an increase in the speed of the valve pin 1040 as it exits upstream and reaches a higher upstream position. Thus, the movement speed of the valve pin 1040 along the X-axis can be varied by the stepped or curved groove shape relative to the constant speed of the linear drive member 150.

[0180] exist Figure 2F , 2G In the embodiments of 2H and 2I, the motion of the motor is converted into the rotational motion of the rotor, the linear motion of the drive components 150 and 940l along the Y-axis, and the non-coaxial linear motion of the valve pin along the X-axis.

[0181] It is easy to imagine that the profile or shape of the groove included in component 507 can be selected as any step, bend, or other nonlinear structure, such that the velocity V of the valve pin 80 along the linear axis X has any selected or predetermined nonlinear or varying correlation with the velocity of the linear drive component 150, in particular such that the velocity along the X-axis changes to one or more preselected velocities, large or small, during the stroke of the valve pin 1040 between the gate closed and gate fully open positions, wherein the velocity of the linear drive component 150 is constant during the same stroke of the valve pin 1040.

[0182] Other linear converters with configurations disclosed in WO2018 / 194961 can be used, which can enable the pins to be driven at different speeds during the injection cycle.

[0183] Figure 3AAnother embodiment of the electric actuator is shown, wherein the actuator (940) has a drive shaft Y coaxial with the stroke axis X of the valve pin (1040), and the actuator housing (940h) is mounted on or physically close to a heating manifold (40) with cooling devices (940mc, 940mc1, 940mc2, 941mc, 942mc) disposed between the heating manifold (40) and the actuator housing (940h, 941h, 942h) and the electric actuator (940d). In this embodiment, the cooling devices are adapted to substantially isolate or insulate the electric actuator (940d, 941d, 942d) from heat dissipated or emitted from the heating manifold (40). The cooling devices are also generally adapted and arranged to isolate or insulate the actuator housing (940h) and the rotation to linear converter (940l) from substantially the heat dissipated or emitted from the heating manifold (40). The cooling equipment is also typically adapted to dissipate heat from the actuator housing (940h) and the rotary-to-linear converter (940l) to the cooling equipment.

[0184] Figure 3B An embodiment is shown in which the actuator (940) has a drive shaft Y coaxial with the stroke axis of the valve pin (1040), and the actuator housing (940h) is mounted on or in direct thermal communication with or in contact with the heating manifold (40) via a seat (940s) mounted on, to, or in direct thermal communication with or in contact with the heating manifold (40). Cooling devices are also generally adapted to dissipate heat from the actuator housing (940h) and the rotating to linear converter (940l) to the cooling device. The seat 940 may be made of a highly thermally conductive material (such as copper) or alternatively, of an insulating material (such as titanium).

[0185] In all embodiments, the electric actuator 940 drives linear drive components, such as drive components 150, 940l, 940ld, and the electromagnetic force 940ef generated by the driver 940r is referred to Figure 21 , Figure 22 The solenoid valves and linear motors directly drive the drive components. The drive shaft A of the selected drive components 150, 940l, and 940ld can be coaxial or non-coaxial with respect to the pin shaft X.

[0186] Figure 4An embodiment is shown in which the actuator (940) has a drive shaft (Y) arranged non-coaxially with respect to the stroke axis of the valve pin (1040). In one iteration (940), the actuator housing (940h) is mounted to the top clamp (80) and directly thermally connected to the heating manifold (40), while the linear stroke converter is instead mounted to or directly thermally connected to the heating manifold (40). In another iteration (940a), the actuator housing may or may not be mounted to the top clamp 80.

[0187] Figure 5 Showing something similar to Figure 2 The apparatus, wherein the actuator (940) has a drive shaft Y arranged non-coaxially relative to the stroke axis X of the valve pin (1040), is mounted on a linear stroke converter (940l) having a housing (940lh), the actuator housing (940h) being mounted to or in direct thermal communication with the heating manifold (40), the housing (940lh) being mounted or mounted on a top clamp (80) via a flange (940lf), the linear stroke converter (940l) being configured to be in direct thermal communication with the heating manifold (40).

[0188] The system includes an actuator (5) comprising a rotor (250) having a drive shaft (Y) and drivers (100, 200) interconnected with the rotor (250). The rotor (250) is adapted to drive the rotor around the drive shaft, and the drivers (100, 200) are... Figure 1 , 4 It receives electrical energy or power that generates driving heat.

[0189] The actuator (5) has an outer casing (20) consisting of radial walls (20r, 20ri, 20rit, 20ro, 20roa, 20rob, 20roc, 20rod) and axial walls (20a, 20ai, 20aue, 20ade). The radial and axial walls form a closed cavity (45) containing a heat-conducting fluid (CF). The rotor and drive (250, 100, 200) are mounted in the cavity (45) in close thermal contact with the heat-conducting fluid. The radial walls 20r, 20ri, 20ro, 20roa, 20rob, 20roc, and 20rod are generally located at a radial position or a Y-axis position relative to the rotor 250. The axial walls are generally located at an axial position or position relative to the Y-axis of the rotor 250.

[0190] Radial walls 20r, 20ri, 20rit, 20ro, 20roa, 20rob, 20roc, 20rod and axial walls 20a, 20ai, 20aue, 20ade are interconnected to form a separate housing 20. The housing is typically detachably attached to the housing 120 of the linear stroke converter or transmission 15 and is preferably easily detachable from the housing 120. The housing 120 of the linear stroke converter or transmission typically includes one or more converter or transmission walls (120r, 120rb, 120rc, 120ri, 120ro, 120a) made of thermally conductive material. The converter or transmission wall (120r, 120rb, 120rc, 120ri, 120ro, 120a) is typically mounted in the arrangement to the heating manifold (300) so that the manifold heat 300 is transferred to the converter or transmission wall (120r, 120rb, 120rc, 120ri, 120ro, 120a).

[0191] like Figure 6 , 6A As shown in 6B, 7, and 7A, one or more radial and axial walls (20r, 20ro, 20ri, 20roa, 20rob, 20roc, 20rod, 20a, 20ai, 20aue, 20ade) are in thermally conductive contact or communication with the heat generated by the manifold (300) or the heat generated by the enclosed cavity (45). One or more radial or axial walls of the actuator housing may include a first unit (20r, 20a, 20ri, 20ai) composed of a thermally conductive material having inner surfaces (20ris, 20ais, 20riis, 20aiis) that are in close thermally conductive contact with the internal space (45s) of the cavity. One or more radial or axial walls include a second unit (20ro, 20ao), the second unit being composed of a thermally conductive material having an inner surface (20rois, 20aois) that is in close thermal contact or communication with the thermally conductive surfaces (20rihcs, 20aihcs) of the first unit (20ri, 20ai) or one or more intermediate units (not shown), the one or more intermediate units being composed of a thermally conductive material and having a second inner surface (20riis, 20aiis) that is in close thermal contact or communication with the internal space (45s) of the cavity (45).

[0192] The actuator tube or channel (25) may be disposed within the second unit (20ro, 20ao). The first unit (20r, 20a, 20ri, 20ai) is typically composed of thermal insulation material, and the second unit (20ro, 20ao) is typically composed of a material with high thermal conductivity.

[0193] In embodiments where the actuator or converter housing wall comprises two or more individual walls (e.g., a first inner wall (20r, 20a, 20ri, 20ai, 120r, 120a, 120ri, 120ai) and a second outer wall (20ro, 20ao, 120ro, 120ao)), the outer wall is preferably connected to the inner wall in a compressed face-to-face contact manner, such that the two or more individual walls connected together function as a single wall to achieve heat absorption and dissipation. The active cooling channel in the outer wall acts to receive and dissipate heat from one or more inner walls connected to the outer wall, as if the cooling channel were located in the inner wall.

[0194] When the motor drivers 100, 200, 940dr, 941dr, and 942dr electrically drive the rotor 250, the motor drivers 100, 200, 940dr, 941dr, and 942dr are heated, and in turn, heat the gas or liquid CF located, contained in, or enclosed within the motor cavity 45. The drivers 100, 200, 940dr, 941dr, and 942dr are in contact with the motor cavity 45. The drivers 100, 200, 940dr, 941dr, and 942dr are typically composed of a conventional motor stator and armature copper or other conductive metal wires or coils. Therefore, when the coils or wires of the actuators 100, 200, 940dr, 941dr, and 942dr are heated, the gas CF in the heating chamber 45 is heated, and the heated gas CF in turn heats the outer casing walls 20r, 20ro, 20ri, 20roa, 20rob, 20roc, 20rod, 20a, 20ai, 20aue, and 20ade that are in contact with the heated gas CF. The rotor 250 and the actuators 100, 200, 940dr, 941dr, and 942dr are rotatably supported within the chamber by the radial and axial walls (20r, 20ro, 20ri, 20roa, 20rob, 20roc, 20rod, 20a, 20ai, 20aue, and 20ade).

[0195] The drives 100, 200, 940dr, 941dr, and 942dr are controllably driven by controllers 16 and 2000, which include programs that can be programmed to controllably position one or more valve pins driven by associated actuator motors that may be included in any injection molding system 1000, either axially or linearly.

[0196] One or more radial and axial walls (20r, 20ro, 20ri, 20roa, 20rob, 20roc, 20rod, 20a, 20ai, 20aue, 20ade) are made of a thermally conductive material, such as steel, aluminum, etc. One or more walls have inner surfaces 20is, 20is, 20is, which are configured to make thermally conductive contact with the thermally conductive fluid (CF) within the enclosed cavity 45. One or more radial or axial walls (20r, 20ro, 20ri, 20roa, 20rob, 20roc, 20rod, 20a, 20ai, 20aue, 20ade) absorb heat from the thermally conductive fluid (CF) within the cavity (45).

[0197] The actuator tube or channel (25) is typically embedded, drilled, or formed within a solid material body of one of the selected radial or axial walls (20r, 20ro, 20ri, 20roa, 20rob, 20roc, 20rod, 20a, 20ai, 20aue, 20ade), such that the tube or channel is surrounded by its circumference and maintains close thermal contact or communication with the thermally conductive material that makes up the radial or axial wall.

[0198] The sources (260) of the actively cooling endothermic fluid (25f) are typically hermetically connected to each other via pipes or channels (25), such that the liquid is actively pumped or delivered through the pipes or channels (25) to a larger active cooling fluid source in a flow that typically absorbs and transfers heat from one or more actuator heat-conducting walls (20r, 20ro, 20ri, 20roa, 20rob, 20roc, 20rod, 20a, 20ai, 20aue, 20ade). The cooling fluid 25f typically comprises water, antifreeze, or similar inert liquids that can be readily pumped through the cooling channels or pipes 25. Where a pipe, opposite to the orifices in the wall material, is used as the carrier for the cooling fluid flow, the pipe 25 is typically composed of a highly endothermic or conductive material (such as copper or the like). And where a pipe is used, it is embedded within the body of the wall material such that the outer perimeter of the pipe wall is in close thermally conductive contact with the wall material.

[0199] As shown in the figure, the valve pin (800) has a pin shaft (X) and is interconnected with the rotor (250) such that the valve pin is oriented or set along a linear travel path (XX) that is usually coaxial with the pin shaft (X).

[0200] System 1000 includes a heating manifold (300) that generates manifold heat. The housing (20) of actuator 5 is typically mounted in thermal communication with the heating manifold (300) such that manifold heat is absorbed or transferred by one or more radial and axial walls (20r, 20ro, 20ri, 20roa, 20rob, 20roc, 20rod, 20a, 20ai, 20aue, 20ade) of the housing to one or more radial and axial walls (20r, 20ro, 20ri, 20roa, 20rob, 20roc, 20rod, 20a, 20ai, 20aue, 20ade).

[0201] One or more radial or axial walls may comprise a monolith (20r, 20ro, 20a, 20a0) composed of a thermally conductive material. The monolith has an inner surface (20ris, 20ais) that can be in direct, thermally conductive contact with the liquid (CF) contained within the cavity.

[0202] Alternatively, the radial or axial wall of actuator 5 may include a first outer unit that is mounted or connected to a second inner or intermediate unit wall (20ri, 20ai). In such an embodiment, the outer unit has an inner surface (20rois, 20aois) in close thermal contact with the intermediate heat transfer surfaces (20rihcs, 20aihcs) of the inner or intermediate unit (20ri, 20ai). In such an embodiment, the inner or intermediate unit wall is composed of a thermally conductive material having a second inner surface (20riis, 20aiis) in direct and close thermal contact with the liquid (CF) contained in the cavity (45).

[0203] In embodiments where one or more radial or axial walls comprise a first outer unit (20ro, 20a0) and a second inner or intermediate unit (20ri, 20ai), the first or outer unit is typically composed of a first thermally conductive material, which is an insulating or low thermally conductive material, such as titanium. Furthermore, the second outer or intermediate unit is typically composed of a high thermally conductive material, such as copper or aluminum.

[0204] The system may also include a linear stroke converter (15) interconnected between a rotor (250) and a valve pin (800), which, in the arrangement, converts the rotational motion of the rotor into the linear motion (XX) of the valve pin (800). The linear stroke converter (15) typically includes a converter housing (120) consisting of one or more converter walls (120r, 120rb, 120rc, 120ri, 120ro, 120a) made of thermally conductive material. The converter walls (120r, 120rb, 120rc, 120ri, 120ro, 120a) may be mounted on a heating manifold (300) in the arrangement such that heat from the manifold is transferred to the converter walls (120r, 120rb, 120rc, 120ri, 120ro, 120a).

[0205] The converter tube or channel (125) is typically embedded or drilled into the body of a selected converter wall (120r, 120rb, 120rc, 120ri, 120ro, 120a) such that the tube or channel 125 is surrounded by and configured to be in close thermal contact with the thermally conductive material of one or more converter walls (120r, 120rb, 120rc, 120ri, 120ro, 120a).

[0206] The source of the heat-absorbing fluid (125f) as described above is typically hermetically interconnected in the arrangement to the converter tube or channel (125) such that the heat-absorbing fluid (125f) is actively pumped or routed through the converter tube or channel (125) in a flow that absorbs heat transferred to the manifold walls of the converter.

[0207] One or more converter walls (120r, 120rb, 120rc, 120ri, 120ro, 120a) may have an outer surface (120aos, 120ros) that is in thermal communication or contact with the thermally conductive surface (20aos) of one or more radial and axial walls (20r, 20ro, 20roa, 20rob, 20roc, 20rod, 20a, 20aue, 20ade) of the actuator (5), such that heat absorbed or contained in the converter wall is conducted or transferred to or from the actuator wall.

[0208] One or more converter walls (120r, 120rb, 120rc, 120ri, 120ro, 120a) may have inner surfaces (120ris, 120ais) configured to be in thermal communication with a linear stroke device (127) interconnected between the rotor (250) and the valve pin, to convert the rotational motion of the rotor into linear motion (XX) of the valve pin (800). In such embodiments, the converter walls are arranged to form a housing or chamber 55, 127c in which the linear stroke device 127 is mounted or disposed. The inner surfaces (120ris, 120ais) of the converter walls are typically in thermal contact with or in communication with the linear stroke device 127.

[0209] One or more of the converter walls may include a single body made of thermally conductive material (120r, 120a, 120ro, 120ao) having an inner surface 120ris, 120ais that is in direct thermal or communicative contact with the cavity 127c or the linear stroke device 127 itself.

[0210] In an alternative embodiment, one or more converter walls may include a first outer unit (120ro, 120ao) and a second intermediate or inner unit (120ri) of thermally conductive material, the first outer unit being connected to the second intermediate or inner unit. In such an embodiment, the outer or first unit 120ro, 120ao has an inner surface (120rois) that is in thermally conductive contact with the thermally conductive surface (120rihcs) of the inner or intermediate unit (120ri). The inner or intermediate unit is composed of a thermally conductive material having a second inner surface (20riis) that is in thermally conductive contact or communication with the linear travel device 127 or with air or gas within cavities 55, 127c.

[0211] In another alternative embodiment, the linear stroke converter (15) may be installed within the same enclosed cavity 45 as the actuators 100, 200, 940dr, 941dr, 942dr that are in contact with the thermally conductive fluid (CF). In such an embodiment, the housing (20) of the actuator 5 is typically mounted in thermal communication with the heating manifold (300), such that heat from the manifold is absorbed or transferred by one or more radial and axial walls (20r, 20ro, 20ri, 20roa, 20rob, 20roc, 20rod, 20a, 20ai, 20aue, 20ade) of the housing 20 to one or more radial and axial walls (20r, 20ro, 20ri, 20roa, 20rob, 20roc, 20rod, 20a, 20ai, 20aue, 20ade). The heat-absorbing fluid (25f) is guided in flow such that heat from the manifold is absorbed or transferred by one or more radial and axial walls of the housing (20r, 20ro, 20ri, 20roa, 20rob, 20roc, 20rod, 20a, 20ai, 20aue, 20ade) to one or more radial and axial walls (20r, 20ro, 20ri, 20roa, 20rob, 20roc, 20rod, 20a, 20ai, 20aue, 20ade). In such an embodiment, the stroke axes of the rotor shaft Y and the valve pins X, XX are typically adapted to be coaxial.

[0212] The system according to the invention may include a transmission device typically consisting of one or more gears, frames, screws, or nuts (16a, 16b, 72, 190, 191, 195, 950, 960, 970), adapted to convert rotational motion of a rotor (250) about a rotor axis Y into linear motion of a valve pin along an axis (X, XX) that is not coaxial with the rotor axis (Y). In such an embodiment, one or more of the transmission walls (120r, 120ro, 120ri, 120a, 120ao, 120ai) form a closed cavity 55 that accommodates or closes one or more of the gears, frames, screws, or nuts (16a, 16b, 72, 190, 191, 195, 950, 960, 970). The one or more transmission walls (120r, 120ro, 120ri, 120a, 120ao, 120ai) are typically made of a thermally conductive material. The converter tube or channel (125) is embedded in or surrounded by a thermally conductive material and is in close thermal contact with the material, wherein the thermally conductive material includes one or more drive walls (120r, 120ro, 120ri, 120a, 120ao, 120ai). As described above, referring to the actuator housing wall, the source of the heat-absorbing fluid (125F) is hermetically interconnected in the arrangement to the converter tube or channel (125), such that the heat-absorbing fluid (125F) is pumped or routed through the converter tube or channel (125) in a flow that absorbs heat absorbed by or transferred to the drive walls (120r, 120ro, 120ri, 120a, 120ao, 120ai).

[0213] In an alternative embodiment, the actuator housing may be detachably mounted and connected to a top clamping or mounting plate 1002, which is mounted upstream of the manifold 300 and interconnected with the mold. The clamping or mounting plate 1002 is typically maintained in a cool state relative to the heating manifold 300, either installed in a spaced relationship with the heating manifold 300 or actively cooled by liquid channels or pipes conveying cooling fluid embedded within the clamping plate 2002 and in close contact with the body of the clamping plate 1002.

[0214] In another alternative embodiment, the housing 120 of the linear stroke converter 15 can be mounted and detachably connected to a top clamping or mounting plate 1002, which is mounted upstream of the manifold and interconnected with the mold. Similarly, the clamping or mounting plate 1002 is generally kept cool relative to the heating manifold 300, either by being installed in a spaced relationship with the heating manifold 300 or by being actively cooled by a liquid channel or pipe conveying cooling fluid embedded within the clamping plate 2002 and in close contact with the body of the clamping plate 1002.

[0215] Typically, one or the other, or both, of the linear stroke converter 15 and the actuator are installed into the heating manifold 300.

[0216] The actuator typically has a housing (20) consisting of radial (20r, 20ri, 20ro, 20roa, 20rob, 20roc, 20rod) and axial walls (20a, 20ai, 20aue, 20ade), which forms a closed cavity (45) containing a heat-conducting fluid (CF). The rotor and actuator (100, 200, 940dr, 941dr, 942dr) are mounted within the cavity (45) in close thermal contact with the heat-conducting fluid. The rotor and actuator are typically supported within the cavity by the radial and axial walls (20r, 20ro, 20ri, 20roa, 20rob, 20roc, 20rod, 20a, 20ai, 20aue, 20ade) in the arrangement, such that the rotor (250) and actuator (100, 200, 940dr, 941dr, 942dr) can be driven to rotate within the cavity (45).

[0217] One or more of the radial and axial walls (20r, 20ro, 20ri, 20roa, 20rob, 20roc, 20rod, 20a, 20ai, 20aue, 20ade) typically comprise a thermally conductive material having an inner surface that maintains thermally conductive contact with the thermally conductive fluid (CF) contained within the enclosed cavity. One or more radial or axial walls (20r, 20ro, 20ri, 20roa, 20rob, 20roc, 20rod, 20a, 20ai, 20aue, 20ade) absorb heat from the thermally conductive fluid (CF) contained within the cavity (45) and have an actuator tube or channel (25) surrounded by and in close thermally conductive contact with the thermally conductive material of the first of the radial and axial walls (20r, 20ro, 20ri, 20roa, 20rob, 20roc, 20rod, 20a, 20ai, 20aue, 20ade). The source (260) of the heat-absorbing fluid (25f) is hermetically interconnected to the pipe or channel (25) in the arrangement, such that the flow of the heat-absorbing fluid (25f) absorbing heat from one or a heat-conducting wall (20r, 20ro, 20ri, 20roa, 20rob, 20roc, 20rod, 20a, 20ai, 20aue, 20ade) is guided through the pipe or channel (25).

[0218] In some embodiments, at least one of the radial walls may include a non-actively cooled monomer (20rot) having an inner surface (20rotis) that is in close thermally conductive contact with the outer surface (20roos) of the first of the radial and axial walls (20r, 20ro, 20ri, 20roa, 20rob, 20roc, 20rod, 20a, 20ai, 20aue, 20ade).

[0219] At least one radial wall of the non-actively cooled unit may also include an intermediate unit (20ri) having a thermally conductive surface (20rihcs) that is in close thermal contact with the inner surface (20rotis) of the non-actively cooled unit (20rot). The intermediate unit is typically composed of a thermally conductive material having a second inner surface (20ris, 20riis, 20aiis) that is in close thermal contact with the liquid (CF) inside the cavity (45).

[0220] The first of the radial or axial walls may include a single body (20r, 20a) composed of a thermally conductive material having an inner surface (20ris, 20ais) configured to be in close thermal contact with the liquid (CF) inside the cavity, or may include a single body (20ro, 20ao) composed of a thermally conductive material having a thermally conductive surface (20rihcs, 20aihcs) in close thermal contact with the inner surface (20rois, 20aois) of an intermediate single body (20ri, 20ai), the intermediate single body being composed of a thermally conductive material having a second inner surface (20riis, 20aiis) configured to be in close thermal contact with the liquid (CF) inside the cavity (45).

[0221] This device includes a heating manifold (300) that generates heat from the manifold, and an actuator housing (20) is mounted in thermal communication with the heating manifold (300), such that the heat from the manifold is absorbed or transferred by one or more radial and axial walls (20r, 20ro, 20ri, 20roa, 20rob, 20roc, 20rod, 20a, 20ai, 20aue, 20ade) of the housing. 0a, 20ai, 20aue, 20ade), the heat-absorbing fluid (25f) absorbs manifold heat absorbed by or transferred to one or more radial and axial walls (20r, 20ro, 20ri, 20roa, 20rob, 20roc, 20rod, 20a, 20ai, 20aue, 20ade) of the outer shell.

[0222] In some embodiments, the device may further include a linear stroke converter (15, 940l) interconnected in the arrangement between the rotor (250) and the valve pins (1041, 800), which converts the rotational motion of the rotor into linear motion (XX) of the valve pins (1041, 800). The linear stroke converter (15, 940l) typically includes a converter housing (120, 940lh) consisting of one or more converter walls (120r, 120rb, 120rc, 120ri, 120ro, 120a) made of thermally conductive material, the converter walls (120r, 120rb, 120rc, 120ri, 120ro, 120a) being mounted in the arrangement to a heating manifold (300) such that manifold heat is transferred to the converter walls (120r, 120rb, 120rc, 120ri, 120ro, 120a). The converter wall includes a converter tube or channel (125), which is surrounded and in close thermal contact with a thermally conductive material of one or more converter walls (120r, 120rb, 120rc, 120ri, 120ro, 120a). A source of endothermic fluid (125F) is hermetically interconnected to the converter tube or channel (125) in the arrangement such that the endothermic fluid (125F) is guided through the converter tube or channel (125) in a flow that absorbs manifold heat transferred to the converter wall.

[0223] In this embodiment, one or more of the converter walls (120r, 120rb, 120rc, 120ri, 120ro, 120a) may have an outer surface (120aos, 120ros) that is in thermal communication with the thermally conductive surface (20aos) of one or more radial and axial walls (20r, 20ro, 20roa, 20rob, 20roc, 20rod, 20a, 20aue, 20ade) of the actuator (5). One or more converter walls (120r, 120rb, 120rc, 120ri, 120ro, 120a) may have an inner surface (120ris, 120ais) configured to be in thermal communication with a linear stroke device (127) interconnected between the rotor (250) and the valve pin to convert the rotational motion of the rotor into the linear motion (XX) of the valve pin (1041, 800).

[0224] In this embodiment, one or more of the converter walls typically include a monolith (120ro) composed of a thermally conductive material having an inner surface (120rois) in thermal contact with a thermally conductive surface (120rihcs) of an intermediate monolith (120ri), the intermediate monolith being composed of a thermally conductive material having a second inner surface (20riis) configured to be in thermal communication with a linear stroke device (127) interconnected between a rotor (250) and a valve pin to convert the rotational motion of the rotor into the linear motion (XX) of the valve pin (800).

[0225] In some embodiments, the rotor (250) has a rotor shaft (Y), and the system may include a transmission device consisting of one or more gears, frames, screws, or nuts adapted to convert rotational motion of the rotor (250) about the rotor shaft (Y) into linear motion of a valve pin along an axis (X, XX) that is not coaxial with the rotor shaft (Y). In this embodiment, one or more transmission walls (120r, 120ro, 120ri, 120a, 120ao, 120ai) form a closed cavity (55) that encloses one or more gears, frames, screws, or nuts, and the one or more transmission walls (120r, 120ro, 120ri, 120a, 120ao, 120ai) are made of a thermally conductive material.

[0226] In some embodiments, the converter tube or channel (125) is surrounded and in close thermal contact with the thermally conductive material of one or more transmission walls (120r, 120ro, 120ri, 120a, 120ao, 120ai). A source of heat-absorbing fluid (125F) is hermetically interconnected to the converter tube or channel (125) in the arrangement such that the flow of the heat-absorbing fluid (125F) absorbing heat absorbed by or transferred to one or more transmission walls (120r, 120ro, 120ri, 120a, 120ao, 120ai) is guided through the converter tube or channel (125).

[0227] In some embodiments, the actuator housing may be detachably connected to a top clamping or mounting plate (1002) which is mounted upstream of the manifold and interconnected with the mold.

[0228] In some embodiments, the linear stroke converter (15) is detachably connected to a top clamping or mounting plate (1002), which is mounted upstream of the manifold and interconnected with the mold.

[0229] Therefore, the linear stroke converter 15 is a device that converts linear motion or rotary motion into linear motion along the X and XX axes, which are different from the Y-axis of the motor.

[0230] Figure 16 Another embodiment is shown, wherein the electric actuator 200 with electric drive 940d is mounted in an extended spacing relationship relative to the heating manifold, such that the actuator and electric drive 940d are substantially or significantly thermally isolated or isolated from the heating manifold 40. In the illustrated embodiment, the actuator and electric drive are mounted on a cool or cooled top clamp 80 and interconnected with a rotation-to-linear drive converter device, which is also mounted to the top clamp. Figure 16 As shown, the electric actuator 200 is mounted on the side surface 140ss of the top clamp 80, and the extension shaft 20 and the converter 940l are mounted within holes or channels 140us, 140uc formed inside or below the top clamp. Similarly, the top clamp 80 is typically cooled by water flowing through cooling channels 145 drilled within the top clamp 80. Figure 16In this embodiment, the converter 940l is mounted to the heating manifold 40 by bolts 58 and springs 56. Bolts 58 allow the converter housing 940lh and its interconnected valve pin 100 to move radially in the R direction along with the radial expansion or movement of the heating manifold, thereby minimizing the need to prevent pin disengagement or deformation due to the radial expansion of the heating manifold 40. Springs 56 elastically and compressibly engage between the upstream surface 60u of the manifold 60 and the downstream surface 40hd of the housing 940lh, so that the upstream heat-conducting surface 40s of the housing 40 is compressibly engaged with the downstream heat-conducting surface 140s of the cooled top clamp 80, thereby transferring heat from the manifold 40 to the housing 940lh to the cooled top clamp 80, thus generally cooling the converter housing 940h and the converter assembly 40c.

[0231] Figure 17 illustrates a conventional prior art pneumatic (or hydraulic) drive 10, with a central nozzle 22 feeding molten material 18 from the injection molding machine IMM through the main inlet 18a into the distribution channel 19 of the manifold 40. The IMM typically includes a barrel (not shown) and a controllably rotary driven or driven screw BS, which initiates and terminates the injection cycle 18 at selected time points as the screw BS rotates to generate the flow of injection fluid. The distribution channel 19 typically feeds three independent nozzles 20, 22, and 24, which generally feed into a common cavity 30 of the mold 33. One of the nozzles 22 is controlled by a liquid-driven actuator 940f and is configured to enter the cavity 30 at an inlet point or gate located approximately at the center 32 of the cavity. As shown, a pair of side nozzles 20, 24 enter the cavity 30 at gate locations 34, 36, distal from the central gate inlet location 32.

[0232] As shown in Figures 17 and 18, the injection cycle using the device according to the invention is most preferably a cascaded process as described in U.S. Patent No. 1,056,945, the disclosure of which is incorporated herein by reference as if fully illustrated herein, wherein injection is first initiated from the central nozzle 22, and then at a later predetermined time, injection is initiated from the side nozzles 20, 24.

[0233] For example, as described in U.S. Patent No. 1,056,945, an injection cycle is initiated by first opening pin 1040 of the central nozzle 22, allowing liquid material 100 (typically a polymer or plastic material) to flow upwards to a position just before the inlet cavities 34, 36 are configured at the distal end of the gate of the side nozzle 24. After the injection cycle begins, the gates of the central injection nozzle 22 and pin 1040 are typically only opened for a short period to allow the liquid material to move to a position just past the location of the downstream gates 34, 36. Once the liquid material has just flowed past the side or downstream gate positions 34, 36, the central gate 32 of the central nozzle 22 is typically closed by pin 1040. The side or downstream gates 34, 36 are then opened by exiting the side nozzle pins 1041, 1042 upstream. The upstream exit speed or travel speed of the side pins 1041, 1042 is typically such that one or both of the downstream pins 1041, 1042 complete the upstream exit path at a relatively slow initial speed or rate, followed by a higher speed, as described in detail in U.S. Patent No. 9,011,736, the disclosure of which is incorporated herein by reference as if fully illustrated herein. The center gate 32 and the associated actuator 940f and valve pin 1040 may remain open when and after the side or downstream gates 34, 36 are opened, allowing liquid material to flow into cavity 30 simultaneously through one or both of the center gate 32 and the side gates 34, 36. When the side or downstream gates 34, 36 are opened, allowing liquid material to first enter the cavity into the stream injected from the center nozzle 22 through the gates 34, 36, the two streams mix. If the velocity of the liquid material is too high, such as when the flow rate of the injected fluid material through gates 34 and 36 reaches its maximum value, noticeable lines or defects from the mixing of the two flows will appear in the area where the liquid is injected into the mold cavity through gates 34 and 36. Visible lines or defects in the final molded product can be reduced or eliminated by injecting the liquid at a lower flow rate for a shorter duration when the downstream gates 34 and 36 first open and when the liquid first enters the first downstream flow.

[0234] The rate or speed of the upstream and downstream strokes of pins 1041 and 1042, starting from the gate closed position or the fully open upstream position, is controlled by actuator controller 16, which controls the speed and direction of pneumatic or hydraulic fluid from drive system 14 to actuators 940f, 941f, and 942f. A predetermined profile of the valve pin or actuator position relative to elapsed time can be input into actuator controller 16 as a basis for controlling the upstream and downstream strokes of valve pins 1041, etc., at one or more selected speeds during the stroke of the valve pins through the length of the upstream or downstream stroke. For example, actuator controller 16 may include instructions instructing the actuator to move at a reduced speed relative to one or more selected higher exit speeds. Typically, a higher speed is selected as the highest speed at which the system can drive the actuator. Typically, the instruction directs the actuator to move the valve pin upward from the gate closed position. During this movement, the tip of the valve pin restricts the flow rate 18 of the injected liquid to a level lower than the flow rate if the valve pin were fully upstream. If the valve pin is fully positioned upstream of gates 32, 34, 36, the flow path or opening at or near gates 32, 34, 36 is restricted to a size smaller than the limit of the opening or flow path size due to the tip of the valve pin.

[0235] In the prior system of Figure 17, actuator controller 16 typically receives signals in real time from pressure sensor 603 (or 605, 607), which is located on the drive fluid line communicating with the outlet of metering valve 600. The signal indicates a decrease in the drive fluid pressure on line 703 (or 705, 707). In systems where an electric motor is used in conjunction with the device of the present invention, actuator controller 16 typically receives signals in real time indicating the position of actuators or pins 1041, 1042. Actuator controller 16 instructs valve gate 600 or electric actuators 941e, 942e to move according to a predetermined profile of the drive pressure or the electric actuator or valve pin position, which affects the initial slow and subsequent rapid movement of the valve pin as described herein.

[0236] As shown in Figure 17, the injection molding machine IMM includes its own in-house manufactured machine controller. The machine controller generates standardized cycle start gate closing and cycle end gate closing and gate closing machine voltage signals, typically 0V for gate open and 24V for gate open (or 0V and 120V respectively). The standardized machine voltage signal VS is typically sent directly to the solenoid of the main directional control valve 12 (which controls the flow direction of actuator-driven liquid into or out of the drive chambers of all the multiple liquid-driven actuators 940f, 941f, 942f) to move the directional control valve 12 (DCV) to the actuator-driven liquid flow position of gate closed or gate open. Alternatively, the same standardized voltage signal VSC can be sent to the directional control valve 12 via the actuator controller 16. In response to receiving the machine screw position signal SPS from the injection molding machine IMM sent to the actuator controller 16, the controller 16 generates the same standardized voltage signal VSC as the VS signal. The actuator controller 16 thus generates the same cycle start and cycle end control voltage signals VSC as the machine IMM and sends them directly to the directional control valve 12. Therefore, if a conventional standardized directional control valve 12 is used, it can be directly connected to an internal signal generator or controller within the injection molding machine via electrical or electronic signal connection, simplifying the transmission of cycle start and cycle end signals.

[0237] Electric actuators or motors and proportional directional control valves cannot directly receive and utilize standard 0V (gate closed), 24V (gate open) or 0V (gate closed), 120V (gate open) signals. These signals are generated by start and stop cycle controllers or signal generators, which are typically included in conventional injection molding machines.

[0238] like Figure 19 As shown in the general schematic diagram, the device 10 according to the invention includes a signal converter 1500, which can receive cycle start and cycle end signals VS (e.g., 0V, 24V, or 120V) generated by a standardized injection machine, and convert the received standardized signals VS into output power signals MOCPS or PDCVS compatible with the power signal reception and use of electric motors or proportional directional control valves. Two different actuator-based systems, namely electric motors and proportional directional control valves, are generally... Figure 11 The text is displayed together for illustrative purposes only. More typically, it is as follows: Figure 11 The actual implementation of the system shown would be such that the converter 1500 would contain a single microcontroller and interconnected drivers, the drivers being configured to work with one or the other of an electric actuator-based system or a proportional directional control valve system.

[0239] Figure 18The device based on an electric actuator is shown in a simplified schematic diagram. For example... Figure 1 As shown, electric actuators 940e, 941e, and 942e each have rotating rotors 940r, 941r, and 942r, which are electrically driven (typically supplied via converter 1500). The precise polarity, amplitude, voltage, and intensity of these rotors are controlled by actuator controller 16 and a program contained within actuator controller 16 to input the motor. The rotating rotors 940r, 941r, and 942r are interconnected with translational movable shafts or other suitable connecting devices 940c, 941c, and 942c, and valve pins 1040, 1041, and 1042 are interconnected with driven rotors 940r, 941r, and 942r. Typical interconnections between rotor-driven shafts and valve pin heads are shown in U.S. Reexamination Certificate 6294122C1 and U.S. Patent No. 9492960, the disclosures of which are incorporated herein by reference in their entirety, as if fully set forth herein.

[0240] Figure 18 A diagram according to the invention is shown, comprising multiple electrically driven actuators 940e, 941e, 942e, wherein a central nozzle 22 conveys molten material 18 from the injection molding machine IMM barrel through a main inlet 18a to a distribution channel 19 of a manifold 40. Figure 2 The device in Figure 3 Figure 1 Like conventional devices, an IMM typically includes a barrel (not shown) and a controllably rotatable, driveable, or self-driven screw BS disposed within the barrel to generate a pressurized supply of injection fluid 18. The pressure of this injection fluid is detected by a barrel pressure sensor BPSR, which sends a signal indicating the barrel pressure to a controller 16 for controlling the positioning and speed of valve pins 1040, 1041, and 1042. The injection cycle of the IMM begins and ends simultaneously with the starting and stopping of screw BS rotation at selected time points. The start of the injection cycle is typically defined as the first selected time point when the screw BS initially rotates from its rest position, or a time point shortly after the screw initially rotates. The end of the cycle is typically defined by a selected second time point after the first selected time point, at which the screw stops rotating and the injection fluid 18 ceases to be injected into the heating manifold 40.

[0241] Distribution channel 19 typically feeds three independent nozzles 20, 22, and 24, which generally feed into the common cavity 30 of mold 33. One of the nozzles 22 is controlled by a motor actuator 940e and is configured to feed into cavity 30 at an inlet point or gate located approximately at the center 32 of the cavity. As shown, a pair of side nozzles 20 and 24 enter cavity 30 at gate positions 34 and 36, located at a distance from the central gate feed position 32.

[0242] Similar to the device in Figure 17, using Figure 18 ,19 The injection cycle of this device is typically used to perform cascaded or sequential valve processes, wherein injection begins first from the central nozzle 22, and then at predetermined times from the side nozzles 20, 24. The cascaded process is discussed in detail herein only as an example, and the invention includes configurations and protocols for injecting a single valve pin and valve gate into a single cavity.

[0243] Similar to the device in Figure 17 Figure 18 , 19 The device 10 includes an actuator controller 16, which typically includes a program that converts standard voltage signals (such as 0V, 24V, 120V) received from the injection molding machine controller MC into command signals IS. The command signals IS are compatible with, can be received by, and can be interpreted by the motor driver MD, causing the motor driver MD to generate motor operation control power signals MOCPS. These motor operation control power signals indicate the start and end of the injection cycle. The start is typically a power signal that drives the motor to retract valve pins 1040, 1041, 1042 from the gate closed position, and the end is a power signal that drives the motor to move the valve pins from the upstream position to the gate closed position. The controller 16 may include a program with commands that can move and drive the valve pins to and along any predetermined position or within a speed field including the reduced speeds described above. Figure 2 In the case of the device, the reduced speed refers to a speed less than the maximum speed at which the electric actuator can drive the pin, usually less than 75% of the maximum speed, and more often less than 50% of the maximum speed, whether upstream or downstream.

[0244] The actuator controller 16 typically includes additional instructions that can instruct valve pins 1041, 1042, 1040 to be driven upward or downward from a fully closed downstream or fully upstream gate open position at one or more reduced upstream or reduced downstream speeds in at least the beginning portion of the upstream travel path of valve pins 1040, 1041, 1042 or in the latter portion of the downstream travel of valve pins toward gates 32, 34, 36, wherein the tip 1142 of pin 1041 restricts the flow of injected fluid through the gate, as shown and described in U.S. Patent No. 10569458.

[0245] In one embodiment, electric actuators 940e, 941e, and 942e are operatively connected to valve pins 1040, 1041, and 1042 in an arrangement, wherein an electric motor drives the valve pin along the A-axis of the valve pin and drives the tip of the valve pin to move between a first position where the tip of the valve pin blocks the gate 34 to prevent injection fluid from flowing into the cavity, and a second position upstream of the first position, wherein the tip of the valve pin restricts the flow 1153 of the injection fluid along at least a portion of the length of the drive path extending between the first and second positions and a third maximum upstream position, wherein the injection fluid material flows freely from the tip of the pin without restriction.

[0246] Motors 940e, 941e, and 942e can be configured and arranged relative to their associated valve pins 1040, 1041, and 1042, as shown in Figure 3, such that the driven rotors 940r, 941r, and 942r and the motor shaft components are axially aligned with the A-axis of the valve pins 1040 and 1041. Alternatively, U.S. Patent No. 9492960 and... Figure 2 , 4 The motor configurations in sections 5 and 6, wherein the drive rotor and shaft assembly are connected to shafts A and X of valve pins 1040, 1041, and 1042, respectively. Figure 2 , 4 Arrange them at a certain angle, 5 or 6.

[0247] In such Figure 18 In the illustrated embodiment, the injection cycle can be initiated by first opening pin 1040 of the central nozzle 22, allowing liquid material 100a (typically a polymer or plastic material) to flow upwards to a position just before the distal inlet 100b of the gate inlet cavities 34, 36 of the side nozzles 24, 20. After the injection cycle begins, the central injection nozzle 22 and the gate of pin 1040 are typically only opened for a short period to allow liquid material 100b to move to position 100p, just past positions 34, 36. Once the liquid material has just flowed past side gate positions 34, 36 at 100p, the central gate 32 of the central nozzle 22 is typically closed by pin 1040 for a predetermined period during the injection cycle. Side gates 34, 36 are then opened by the upstream exit of side nozzle pins 1041, 1042.

[0248] In an alternative embodiment, the center gate 32 and its associated actuator 940e and valve pin 1040 may remain open at the moment, during, and after the side gates 34, 36 are opened, allowing liquid material to flow into cavity 30 simultaneously through one or both of the center gate 32 and the side gates 34, 36. When the side gates 34, 36 are opened, allowing liquid material 100a to enter the mold cavity first, entering the flow injected from the center nozzle 22 through gates 34, 36, the two flows mix. If the velocity of the liquid material is too high, such as when the flow rate of the injected fluid material through gates 34, 36 is at its maximum, noticeable lines or defects may appear in the final cooled molded product injected into the mold cavity at gates 34, 36. By injecting liquid from the downstream gates 34, 36 at a lower flow rate for a shorter period of time starting from the initial opening of the downstream gates 34, 36, and then after the time when the liquid first enters the flow 100a, the appearance of visible lines or defects in the final molded product can be reduced or eliminated.

[0249] The signal converter 1500 is provided. Figure 18 ,19 This allows users to connect the standardized voltage signal outputs (VS, VSC) of traditional IMM controllers to motors 940e, 941e, and 942e. Figure 2 The input of numbers 1, 2, 3, 4, 5, 6, 10, 11, and 12 is in the same manner as the user's input. Figure 1 The IMM controller in a traditional device is connected to the DCV in the same way. The signal converter 1500 receives and converts the received IMM voltage signal (e.g., 0V, 24V, 120V) into control signals (MOCPS or PDCVS for starting and ending the loop). Figure 10 , 11 As shown in Figure 12, the standardized voltage signal VS can be generated by an HPU (Hydraulic Power Unit) that is physically independent but connected to the machine controller MC. Figure 10 , 11 12) Receive the cylinder screw position signal SPS from the machine controller and generate a corresponding standardized VS signal. The standardized VS signal is then sent to the controller 16 to be converted into a command signal. The command signal can be used by the motor driver MD or the proportional directional control valve driver HVD, PVD to drive the motor or proportional directional control valve to start and end the injection cycle.

[0250] Therefore, the standard start and stop control signals generated by the IMM (VS, VSC) can be operated together with the converter 1500 to instruct the electric actuators 940e, 941e, 942e or the liquid-driven actuators 940p, 941p, 942p to start or begin at least one injection cycle (e.g., by instructing the actuators 940e, 941e, 942e, 940p, 941p, 942p to drive the valve pin upstream from the gate closed position) and end or stop one injection cycle (e.g., by instructing the actuators 940e, 941e, 942e, 940p, 941p, 942p to drive the valve pin downstream from the gate open position to the gate closed position).

[0251] Most preferably, the physical or mechanical electrical signal connectors typically used for connecting wires or cables from the IMM (or machine controller MC) to the signal conversion device 1500 are the same physical or mechanical connectors used in conventional equipment for connecting the IMM (or machine controller MC) to the DCV of conventional equipment, such as... Figure 10 As shown.

[0252] like Figure 18 , 19As shown in Figure 20, the IMM's signal output VS can be directly connected to the signal converter 1500. The signal converter 1500 converts the VS signal into a motor on / off power signal MOPCS or a proportional directional control valve signal PDCVS. This signal is compatible with and can be processed by motors 940e, 941e, 942e or proportional directional control valves V, V1, V2. Alternatively, Figure 10 , 11 The signal output of the IMM of the machine controller MC in embodiment 12 may include a barrel screw position signal SPS sent to the intermediate HPU unit via the screw position sensor SPSR.

[0253] MOCPS and PDCVS signals include signals corresponding to the VS signals that operate to affect the start and end of the injection cycle.

[0254] Typically, Figure 18 The device 10 includes one or more position sensors 950, 951, 952 or other sensors SN, SC, which detect the selected state of the injected fluid 18 in one or more manifold liquid flow channels 19, nozzle flow channels 42, 44, 46 or mold cavity 30.

[0255] The actuator controller 16 may include a program that receives and processes real-time signals indicating the state of the injected fluid 18 or components of the device (10), such as the rotational positions of rotors 940r, 941r, 942r or the axial linear positions of valve pins 1040, 1041, 1042. The real-time signals sent and received by the actuator controller 16 are generated by one or more of position sensors 950, 951, 952 or liquid state sensors SN, SC. ​​The sensors detect and send signals to the actuator controller, typically indicating the rotational positions of one or more rotors 940r, 941r, 942r (sensors 950, 951, 952) or the linear axial positions of valve pins 1040, 1041, 1042. The liquid state sensors typically include one or more pressure or temperature sensors SN that sense the pressure or temperature of the injected fluid 18 in the manifold passage 19 or nozzle passages 42, 44, 46, or in the cavity 30 of the mold 33.

[0256] The actuator controller 16 may include a program that processes signals received from one or more of the sensors 950, 951, 952, SN, SC according to a set of instructions. The instructions use the received signals as variable inputs or other bases for controlling one or more positions or speeds of the actuators 940e, 941e, 942e or their associated valve pins 1040, 1041, 1042 through the injection cycle duration or through all or part of the upstream or downstream stroke length of the actuators 940e, 941e, 942e.

[0257] As shown, controller 16 may be included in converter 1500 ( Figure 10 , 11 The components within (12) and the components containing the converter. The converter 1500 includes a controller 16 containing position and speed control commands. Therefore, the converter 1500 can send its machine on / off power signal MOCPS (or valve on / off signal PDCVS) along with a position / speed signal (PVS) to the electric actuators 940e, 941e, 942e or proportional directional control valves V, V1, V2. Thus, the control signals MOCPS and PDCVS include signals converted and corresponding to one or the other of the converted VS signals received by the converter 1500 from the IMM controller MC or HPU. The position or speed control signal PVS can control the position or speed of the valve pin according to any predetermined pin position or speed profile over the injection cycle time. The form, format, intensity, and frequency of the MOCPS, PDCVS, and PVS signals are compatible with the signal receiving interfaces of the electric actuators 940e, 941e, 942e or valves V, V1, V2.

[0258] exist Figure 2A , 2B In the embodiments shown in 2BB, 2C, 2D, and 2E, the controllable rotational shaft of the electric actuator 940 is downstream interconnected to the reduction gear 46. In a specific embodiment shown, the reduction gear 46 includes a strain wave gear, which in turn connects to an eccentric pin drive mechanism 940l that converts the rotational motion of the valve pin 1040 into linear motion. In such an embodiment, the valve pin 1040 may be interconnected or engaged with a cam member 600, which is eccentrically driven about an output rotational shaft (such as the shaft 12a of a motor rotor or the shaft R3 of the reduction / torque amplification device 46). The eccentricity of the cam member 600 enables variable speed and higher torque control of the linear drive motion of the pin 1040 along the linear axis A.

[0259] exist Figure 3A , 3B In embodiments 13A and 14A, the motor rotor shaft is coaxial with the valve pin shaft, so the actuator housing (940h, 941h, 942h) is mounted on the cooling device (940mc) via a heat-insulating seat (60) and is in direct thermal contact with the cooling device (940mc). The seat (60) may be adapted to form a heat-insulating gap (G') between the cooling device and one or both of the housing (940h) and the electric actuator (940d).

[0260] Similarly, for example, Figures 2A to 2EAs shown in the embodiment, the motor rotor shaft (Y) is arranged non-coaxially with respect to the travel axis (X) of the valve pin (1040), and the seat (60) is adapted to form a gap (G') between the cooling device (940mc) and the rotating linear converter (940l, 941l, 940h, 941lh). In these embodiments, the seat (60) also effectively forms a thermally insulating gap (G') between the actuator housing (940h) and the rotary-to-linear converter (940l, 941l, 940h, 941lh), taking advantage of the intermediate interconnection between the actuator housing (940h) and the rotary-to-linear converter (940l, 940lh) and the electric actuator (940d) by mounting the rotary-to-linear converter (940l, 940lh) to the cooling device (940mc). Figure 2BB .

[0261] Figures 2A to 2E The specific strain wave gear and downstream eccentric to linear drive mechanism are described in detail in U.S. International Application Publication WO2019 / 100085A1, the disclosure of which is incorporated herein by reference in its entirety as if fully elaborated in this document.

[0262] like Figure 2D As shown, the converter 940l may include a seat or alignment bracket 40a and a trolley or slider 43 interconnected with a valve pin 100. The alignment bracket 40a has a guide surface 40as, and a complementary surface 43s of the trolley or slider 43 slides relative to the guide surface 40as when the trolley 43 is reciprocated along a linear path A by an eccentric drive assembly including a cam member 47. The trolley 43 has a freely rotatable wheel 43r that facilitates sliding the trolley upstream and downstream of the surface 40a. In an alternative embodiment, the wheel 43r is not necessary, and the side surfaces 43s may be adapted to slide directly relative to the surface 40as without the wheel. The alignment bracket 40a is connected to a rotary reducer 46. The converter 940l is mounted to a heating manifold 60 as shown.

[0263] The converter 940l includes a drive or mounting wheel or disc 500 having a rotation center 500c, which is axially connected or interconnected directly or indirectly to a rotatable drive shaft 12 of the actuator 940 via rotatably interconnected elongated shafts 20, 20f or connector shafts (e.g., splined shafts 42s). An electrically driven rotor or transmission shaft 12 of an electric motor is rotatably interconnected to the center 500c of the drive wheel or disc 500 rotating to the linear converter 940l mechanism. An eccentrically mounted cam member 600, typically a freely rotatable disc or wheel, is mounted on the rotatable driven disc or wheel 500, with an eccentric distance ED from the rotation center 500c of the driven wheel or disc 500.

[0264] The electric drive of the motor rotor 12 drives the drive wheel 500 to rotate R3 at a controllable selectable speed and direction. As shown, the drive wheel 500 of the converter 940l is rotatably driven, and the eccentrically mounted cam member 600 rotates R3 about the center 500c of the drive wheel 500. As shown, the converter 940l includes a slider or carriage 43 with a cam groove 43sl, which is connected in arrangement to a bracket 40a such that the outer peripheral surface 600cs of the cam member 600 engages with the complementary inner cam surface 43ss of the slider or carriage 43. The cam surface 43ss of the slider 43 is configured relative to the diameter D and eccentric distance ED of the cam member 600 to force the outer surface 600cs of the cam member 600 into contact with the inner surface 43ss of the slider 43, thereby causing the slider 43 to rotate eccentrically about the center of the driven disc or wheel member 500 by R3, such that the slider 43 rotates in the linear direction or along the A-axis. Figure 5-9 The valve pin 100 is forcibly driven up and down or back and forth along a linear direction. As shown in the figure, the valve pin 100 is fixedly connected to the driven slider or slide member 43 in the arrangement, so that the valve pin 100 and the linear movement A of the slider 43 are linearly driven together.

[0265] Because the cam member 600 is eccentrically mounted, the linear or axial velocities A31, A32, and A33 of the valve pin 1040 and the trolley 43 along the linear path A vary according to the rotational or angular position changes A31, A32, and A33 of the cam member 600 during a constant rotational speed R3. When the cam member 600 is in a 90-degree rotational position, the linear or axial velocity A32 is at its maximum value; when the cam member 600 is in a 45-degree position and a 135-degree rotational position, the linear or axial velocity A32 is at a lower value.

[0266] Conversely, due to the eccentric mounting of the cam member 600, the torque exerted by the eccentric cam 600 on the valve pin 1040 and the trolley 43 along the straight path A varies with the rotational or angular position of the cam member 600, while the rotational speed R3 remains constant. The torque is minimal when the cam member 600 is positioned at a 90-degree rotational position, and higher when the cam member 600 is positioned at 45-degree and 135-degree rotational positions.

[0267] The absolute maximum torque position is the position of the cam at the absolute maximum torque position, which is usually the 0-degree position or the 180-degree position.

[0268] The rotation of the cam member 600 can be restricted to a full 360-degree arc less than the rotation of the shaft or output device, for example, between 70 degrees above and below the 90-degree and 270-degree positions, and most preferably between 40 degrees above and below the 90-degree and 270-degree positions.

[0269] The cam device (600) is arranged eccentrically or off-center at a selected distance (ED, R) from the output rotation axis (12a, R3a) such that when the axis (12a) or rotation causes (16, 430, 500) to be rotatably driven about the output rotation axis (12a, R3a), the cam member (600) is eccentrically rotatably driven about the output rotation axis (12a, R3a) to selectable angular positions above and below 270 degrees or 90 degrees. Figure 6A , 6B 6C).

[0270] In this preferred embodiment, the controller (16) is interconnected with the shaft (12) or the output rotating device (16, 430, 500). The controller (1000) may include an algorithm that controllably limits the rotation of the shaft (12) or the output rotating device (16, 430, 500) to an angular position between approximately 70 degrees above and below a 270-degree position, or between approximately 70 degrees above and below a 90-degree position, throughout the injection cycle. The preselected angular position between the 270-degree or 90-degree position and the 70-degree position above defines a fully open pin position (PFO), and the preselected angular position between the 270-degree or 90-degree position and the 70-degree position below defines a pin closed position (PFC).

[0271] As shown, the slider, trolley, or linear travel device (43, 40) is adapted to guide the valve pin along a linear path of travel (A, AS). The rotation to linear converter device (40, 43) may include a stop or linear travel limiter (not shown) fixed to the alignment bracket 40a of the rotation to linear converter 940l, or otherwise fixedly connected relative to the trolley 43. The stop is typically mounted to and adapted to limit the linear movement of the slider or trolley 43 such that when the cam member 600 rotates to a preselected maximum angular position of 70 degrees or less than 270 degrees (or 90 degrees), the travel of the cam 600 and the valve pin stops. Typically, such preselected maximum angular positions above and below 270 degrees or 90 degrees are selected to define the corresponding preselected fully open valve position (PFO) and the corresponding fully closed valve position (PFC).

[0272] The algorithm can controllably restrict the rotation of the shaft (12) or the output rotating device (16, 430, 500) to an angular position between approximately 40 degrees above and below a 270-degree position or between approximately 40 degrees above and below a 90-degree position throughout the injection cycle. The preselected angular position between 40 degrees above or below 270 degrees defines the fully open valve pin position (PFO), and the preselected angular position between 40 degrees below or below 270 degrees defines the gate closed valve pin position (PFC).

[0273] An alternative method for describing how to limit the rotation of cam 600 is that the algorithm of controllers 16, 1000 limits the rotation of shaft (12) or output rotating device (16, 43, 500) to a selectable angular position created by a torque arm M extending between a selected minimum torque arm M2 and a selected maximum torque arm M1. The selectable angular position is between 70 degrees above and 70 degrees below a pre-selected angular position (270 degrees) corresponding to the selected maximum torque arm M1. Typically, an absolute maximum torque arm M1 exists when the rotation or angular position of cam 600 is set to 270 degrees or 90 degrees, although other angular positions can be pre-selected to define or correspond to the absolute maximum torque arm position.

[0274] As shown, the driven wheel or disc assembly 500 is typically mounted on the positive 500m of the driven wheel or disc assembly 700 of the reduction gear 46, and the speed of the reduction gear 46 is reduced relative to the speed of the rotor or drive shaft 12 of the actuator 200.

[0275] The rotary reduction device 46 may include a strain wave gear, which comprises a rotatable elliptical or other non-circular, such as a three-node containing a disc or ring, which produces a reduction in the output speed relative to the input rotor's rotational speed. The strain wave gear typically consists of three basic components: a wave generator, a bent spline, and a circular spline. The wave generator is typically composed of an elliptical or other non-circular, such as a three-node containing a disc, called the wave generator plug, and an outer ball bearing, which has an elliptical or other non-circular shape, such as a three-node shape. The bent spline is typically shaped like a shallow cup. The circumferential sidewalls of the spline are very thin, but the bottom is relatively rigid. This results in significant flexibility of the walls because the thin walls are quite rigid at the open end and on the closed side, allowing them to be firmly secured to the output shaft. The teeth are radially positioned on the outside of the bent spline. The bent spline fits tightly against the wave generator, so that when the wave generator plug rotates, the bent spline deforms into a rotational elliptical shape or other non-circular shape (such as a three-section shape) and does not slip on the outer elliptical shape or other non-circular shape (such as a three-section shape) of the ball bearing. The ball bearing allows the bent spline to rotate independently to the axis of the wave generator. The circular spline is a rigid circular ring with internal teeth. The bent spline and the wave generator are positioned within the circular spline, so that the teeth of the bent spline mesh with the teeth of the circular spline. Because the bent spline is deformed into an elliptical or other non-circular shape, such as a three-section shape, its teeth actually only mesh with the teeth of the circular spline in two regions on opposite sides of the bent spline (located in the elliptical or other non-circular shape, such as a three-section shape).

[0276] As the wave generator plug rotates, the position of the bent spline teeth meshing with the circular spline changes. The main shaft of the bent, sliding elliptical or other non-circular (such as a shape containing three segments) rotates together with the wave generator; therefore, the point of meshing teeth rotates around the center point at the same speed as the wave generator shaft. A key design element of strain wave gears is that the bent spline has fewer teeth than the circular spline (typically, for example, two fewer). This means that for each complete rotation of the wave generator, the bent spline will need to rotate backward a small amount relative to the circular spline (two teeth in this example). Therefore, the rotational action of the wave generator causes the bent spline to rotate much slower in the opposite direction. For strain wave drives, the gear reduction ratio can be calculated using the number of teeth on each gear.

[0277] The device most preferably includes position sensors 950, 951, and 952 that sense the rotational position of the rotor 12 of the electric actuator or motor 200, or includes a position sensor that senses the linear position of the valve pin 1040 or a linear motion member (such as a trolley 43) that moves with the linear movement of the valve pin 1040. Figure 1 , 2In the embodiments, the position sensor typically includes an encoder that senses the rotational position of the rotating element of the rotor 12 or strain wave gear 400 (e.g., the bent spline 430), which in turn corresponds to the linear position of the pin 1040. The linear position sensor PS may include a Hall effect sensor (HES or HES) that senses changes in the magnetic field generated by a magnet mounted on the pin 1040 and moves linearly along with the linear movement of the pin 1040, translating the magnetic field changes into the position of the valve pin 1040.

[0278] In the illustrated embodiment, the strain wave gear 400 consists of a wave generator or a thin-walled bearing 460, which is mounted on and rests against the inner peripheral wall of the curved spline 430, while the curved spline 430 is instead mounted within the inner spline circumference of the rigid circular spline 448, for example as... Figure 2C , 2D As shown in Figure 2E, an inner bearing ring 464, pressed against an elliptical or other non-circular shape (such as the three-section surface of hub 472), has or adopts a shape complementary to the shape of the cam or an elliptical or other non-circular shape (such as the three-section surface of hub 472), and transmits force 470 via ball bearing 466 to an outer ring 462, which is also typically elliptical or other non-circular (such as a three-section shape), and to curved spline teeth 444, which force them to mesh with ring gear teeth 446 as the cam rotates on shaft 12.

[0279] The input shaft includes a motor shaft 12 that rotates about axis 12a, the outer surface of which compressively engages with the inner circumferential surface 480 of the shaft receiving hole 474 of the gear hub. In the illustrated embodiment, the output shaft or disc is the inner ring 414 of the output bearing 410, the interface surface 420 of which connects to the complementary end face 432 of the bent spline 430. The strain wave gear, as shown, consists of a housing 400 on which a slewing ring bearing is mounted at its front end. The outer ring 412 of the bearing is bolted to the housing, and the inner ring 414 is part of an armature 418 supported by rollers 416. The slewing ring bearing provides superior stability against any forward to backward movement of the armature as it rotates within the housing. The front end or front face 422 of the armature has a bolt pattern 424 on which the drive disc 500 is fastened by screws 428 passing through the bolt pattern 502. The cam member 600 is connected to the armature 418 via a bolt in a hole in bolt pattern 502 of the drive disc 500 and rotates eccentrically a distance ED about the output rotation axis R3a. Shoulder bolts 602 clamp a boss 604 onto the disc 500, which is driven to rotate about the gear reducer's rotation axis. The boss forms the inner ring of the roller bearing 606. The outer ring 608 has an outer surface 600cs that drives the trolley up and down. At the rear end 420 of the armature, there is bolt pattern 426, which is bolted to a bent spline 430. The bent spline is cup-shaped. The front end 432 is closed and has bolt pattern 436 for securing the end of the bent spline to the armature via clamp 436 and bolts 438. The sidewalls 440 of the bent spline are thin for flexibility but maintain good torsional strength. The rear end of the cup-shaped 442 is open to receive a wave generator 460. The outer surface of the rim has gear teeth 444, which selectively mesh with a ring gear 448 when the wave generator rotates. The wave generator is mounted on the motor drive shaft 12 via a hub 472. The hub 472 has a hole 474 with a compressible wedge sleeve 480. When the screws 478 are tightened, they force the clamping ring 476 to compress the sleeve backward and self-center, clamping the hub to the shaft 12 without the need for Allen set screws or keyways for smoother operation. The wave generator 460 consists of an elliptical cam formed on the hub 472, on which a ball bearing assembly is mounted by force engagement. The ball bearing assembly has a curved inner ring that is force-engaged to the cam portion of the hub 472. The blades 482 on the hub form the inner ring 464 as a cam with two blades 468 formed by 180-degree elliptical separation.The outer ring 462 can be rigid and elliptical or other non-circular in form, such as a three-node shape complementary to an elliptical shape, or other non-circular, such as the three-node shape of the hub 472 and the inner ring 464. Alternatively, it can be thin and curved, thus conforming to the shape of the cam, causing it, along with the ball bearing 466, to project outwards (arrow 470) as the shaft 12 rotates, forcing the gear teeth 444, 446 to mesh at position 450. After the teeth 444 bend inwards at position 452, the sprocket has passed through, allowing the clearance for one or more teeth 444 to skip over the ring gear teeth 446, and allowing the curved spline 430 to rotate relative to the ring gear 448, as determined by the gear ratio and the number of teeth.

[0280] The arrangement of the components of the operating strain wave gears 46, 400 (wave generator, bent spline, circular spline) is inherently nested to provide physical device depth GD, diameter DIA, or physical dimensions that are compact, space-efficient enough, or sufficient to allow the device to be mounted in the housing of the rotary linear converter 40, and is suitable for mounting to and from one or the top clamp and heating manifold (alone or together with the rotary linear converter).

[0281] Alternatively, the speed reduction and torque increase device may include components (such as worm gear assemblies, spur gear assemblies), planetary gear assemblies, wherein the rotor 12 of the motor is connected to and rotates the highest-speed rotating gear or gear-tooth assembly, and an intermediate shaft is connected to and driven by the highest-speed rotating gear or gear-tooth assembly to effectively reduce the speed and increase the torque output of the rotor 12, which is then transmitted to an output shaft driven at a reduced speed and higher torque. Other components, such as helical gear assemblies, or belt and pulley devices and assemblies, may be used to influence this speed and torque variation.

[0282] 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, hardware, combinations 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 file, an execution thread, a program, and / or a computer. By way of description, an application running on a server and the server itself can both be components. One or more components may reside in a process and / or an execution thread, and components may be located on a single computer and / or distributed across two or more computers.

[0283] The methods protected by the claims of this invention can also be represented as a process flow diagram of the invention. Although, for the sake of simplicity, one or more methods shown in the form of a flow diagram are described as a series of actions, it should be understood and appreciated that the invention is not limited to the order of actions, as some actions may occur in a different order than those shown and described herein and / or occur simultaneously with other actions according to the invention. For example, those skilled in the art will understand and appreciate that the method can instead be represented as a series of interrelated states or events, such as in a state diagram. Furthermore, not all actions shown need to implement the method according to the invention.

[0284] In the various embodiments of the invention disclosed herein, the term "data" or the like refers to any sequence of symbols (typically represented as "0" and "1") that can be input into a computer, stored and processed in a computer, or transferred to another computer. As used herein, data includes metadata, descriptions of other data. Data written to memory can be data elements of the same size or data elements of different sizes. Some examples of data include information, program code, program state, program data, other data, etc.

[0285] As used herein, computer storage media or the like 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 include RAM, ROM, EEPROM, FLASH memory or other storage technologies, CD-ROM, digital versatile optical disc (DVD) or other optical disc storage, magnetic tape, magnetic disk storage or other magnetic storage devices, or any other medium that can be used to store desired information and is accessible by a computer.

[0286] The methods described herein can be implemented in suitable computing and storage environments, such as in the context of computer-executable instructions that can run on one or more processors, microcontrollers, or other computers. For example, in a distributed computing environment, certain tasks are performed by remote processing devices connected via a communication network, and program modules can reside in both local and remote memory storage devices. The communication network can include global area networks, such as the Internet, local area networks, wide area networks, or other computer networks. It should be understood that the network connections described herein are exemplary, and other methods for establishing communication between computers can be used.

[0287] A computer may include one or more processors and memory, such as processing units, system memory, and a system bus, wherein the system bus connects system components, including but not limited to system memory and processing units. A computer may also include disk drives and interfaces to external components. Various computer-readable media can be accessed by the computer, including volatile and non-volatile media, removable and non-removable media. A computer may include various user interface devices, including displays, touchscreens, keyboards, or mice.

[0288] As used herein, "controller" also refers to electrical and electronic control devices, which include single or multiple boxes (typically interconnected and communicating with each other) containing all the individual electronic processing, memory, and electrical signal generation components necessary or required to perform and construct the methods, functions, and devices described herein. These electronic and electrical 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 duration, degree of electrical signal output, etc. For example, components of a controller, as used herein, include programs, controllers, etc., that perform functions such as monitoring, alarming, and initiating injection molding cycles. These include control devices used to perform conventional functions such as signaling and instructing a single injection valve or a series of interdependent valve gates to initiate injection (i.e., moving the actuator and associated valve pin from the gate closed position to the gate open position). Furthermore, although liquid-driven actuators are used in typical or preferred embodiments of the invention, actuators driven by electric or electronic motors or drive sources may alternatively be used as actuator components.

[0289] The actuator controller 16 typically includes additional instructions that can direct valve pins 1041, 1042, 1040 to be driven upward or downward from a fully closed downstream or fully upstream gate open position at one or more reduced upstream or reduced downstream speeds in at least the beginning portion of the upstream travel path of valve pins 1040, 1041, 1042 or in the latter portion of the downstream travel of valve pins towards gates 32, 34, 36, wherein the tip 1142 of pin 1041 restricts the flow of injected fluid through the gate, as shown and described in U.S. Patent No. 10569458.

[0290] In one embodiment, electric actuators 940, 941, 942 are operatively interconnected in an arrangement to valve pins 1040, 1041, 1042. An electric motor drives the valve pin along its A-axis and drives the tip of the valve pin between a first position and a second position upstream of the first position. In the first position, the tip of the valve pin blocks the gate 34 to prevent injection fluid from flowing into the cavity. The tip of the valve pin restricts the flow 1153 of the injection fluid along at least a portion of the length of the drive path extending between the first and second positions and a third maximum upstream position. In the third maximum upstream position, the injection fluid material flows freely from the tip of the pin without restriction.

[0291] In such Figure 1 In the illustrated embodiment, the injection cycle can be initiated by first opening pin 1040 of the central nozzle 22, allowing liquid material 100a (typically a polymer or plastic material) to flow upwards to a position just before the distal inlet 100b of the gate inlet cavities 34, 36 of the side nozzles 24, 20. After the injection cycle begins, the central injection nozzle 22 and the gate of pin 1040 are typically only opened for a short period to allow liquid material 100b to move to position 100p just past positions 34, 36. Once the liquid material has just flowed past side gate positions 34, 36 at 100p, the central gate 32 of the central nozzle 22 is typically closed by pin 1040 for a predetermined time during the injection cycle. The side gates 34, 36 are then opened by exiting the side nozzle pins 1041, 1042 upstream.

[0292] In an alternative embodiment, the center gate 32 and its associated actuator 940e, as well as the valve pin 1040, can remain open at the moment, during, and after the side gates 34, 36 are opened, allowing liquid material to simultaneously flow into cavity 30 through one or both of the center gate 32 and the side gates 34, 36. When the side gates 34, 36 are opened, allowing liquid material 100a to enter the mold cavity first, it enters the flow already injected from the center nozzle 22 through gates 34, 36, and the two flows mix. If the flow rate of the liquid material is too high, such as when the flow rate of the injected fluid material through gates 34, 36 is at its maximum, noticeable lines or defects may appear in the final cooled molded product in the area where the liquid is injected into the mold cavity through gates 34, 36. By injecting from the downstream gates 34, 36 at a lower flow rate for a shorter period of time, starting from the first opening of the downstream gates 34, 36, and then after the time when the liquid first enters the flow 100a, the appearance of visible lines or defects in the final molded product can be reduced or eliminated.

[0293] Affecting drive components (such as rod 940l or plunger 940ld), Figure 21 , 22 A linear actuator that directly linearly drives motion can be used as a reference. Figures 1 to 12 The rotary motion described in the embodiment or the alternative use of the rotor-based actuator 940.

[0294] An example of a linear actuator is as follows Figure 21 The proportional solenoid shown influences the simulated positioning of the electromagnetic plunger or rod 940ld as a function of the coil current contained in the armature or actuator 940dr. Figure 21 The solenoid shown, or Figure 22 The linear motor shown employs a flux-carrying geometry that generates a high starting force on the plunger or rod 940ld, thereby allowing the plunger or rod 940ld to be controllably driven along the linear drive shaft Y. As the solenoid progresses through its operating stroke, the resulting force (torque) profile is almost flat or decreases from a high value to a lower value. Solenoid valves can be used to position, stop the mid-stroke, or for low-speed linear actuation of the plunger or rod 940ld, particularly in closed-loop control systems. The proportional concept is described more fully in SAE Publication 860759 (1986), the disclosure of which is incorporated herein by reference as if fully expounded herein. Another example of a linear actuator is the linear motor. Figure 22 It does not generate torque (rotation), but rather a linear force along its drive axis Y. A typical operating mode is as a Lorentz-type actuator, where the applied force is linearly proportional to the applied current and magnetic field. Therefore, a linear actuator 940, influencing the linear drive motion of a rod, plunger, or equivalent element 940ld, can be used as an alternative device interconnected with the valve pin 1040 to achieve controllable driven linear motion of the reversible movement of the valve pin 1040 along its X-axis, as described above.

[0295] Linear actuators are particularly suitable for use in configurations where the actuator's drive axis Y and pin axis X are arranged coaxially, for example, in reference... Figure 3A , 3B The described embodiments.

Claims

1. An injection molding apparatus, comprising: A heatable manifold (40) is configured to receive molten injection fluid (18) from an injection molding machine (13) and substantially maintain the molten injection fluid at a selected temperature; One or more nozzles (20, 22, 24); A flow channel (19) is formed through at least one of the heated manifold (40) and one or more nozzles, the flow channel being configured to receive the molten injection fluid through the heated manifold (40) and deliver the molten injection fluid to a gate (32, 34, 36) of the mold cavity (30). The electric actuators (940d, 941d, 942d) have an interface configured to receive and distribute electrical energy in a controllably varying amount during an injection cycle. Valve pins (1040, 1041, 1042); Actuators (940, 941, 942), which are connected to the valve pin and configured to control the flow of the molten injection fluid to the mold cavity (30) by controllably moving the valve pin, the actuators having: A driver (940dr, 941dr, 942dr), the driver (940dr, 941dr, 942dr) being configured to receive controllably varying electrical energy from the electric driver (940d, 941d, 942dr) and to drive the actuator (940, 941, 942) in response to the controllably varying electrical energy from the electric driver; and Actuator housings (940h, 941h, 942h) that house the actuators (940dr, 941dr, 942dr), wherein the electric actuators (940d, 941d, 942d) are housed within, or by, the actuator housings (940h, 941h, 942h), or mounted on or to the actuator housing via drive mounts (940ds, 941ds); One or more sensors (950, 951, 952), said one or more sensors (950, 951, 952) are configured to generate one or more sensor signals to indicate one or more of the following: The rotational position of the actuators (940, 941, 942); The linear position of the actuators (940, 941, 942); The position of the valve pins (1040, 1041, 1042) associated with the actuators (940, 941, 942); An actuator controller (16) is configured to respond to at least one of the one or more sensor signals to direct at least one operation of the actuator (940, 941, 942) or its associated valve pin (1040, 1041, 1042), the at least one operation including: During the injection cycle, it moves to a position corresponding to a predetermined profile, wherein the predetermined profile is associated with a linear or rotary pin position and a linear actuator or valve pin position; Exit from the closed gate position upstream at a reduced speed along the selected upstream travel path; The valve pin travels downstream at a reduced speed along a selected downstream travel path, wherein the distal tip of the valve pin moves to the gate closed position; or The valve pin is moved upstream or downstream to an intermediate position between the gate closed position and the fully upstream position, wherein the valve pin is held in the intermediate position for a selected period of time during the injection cycle, and wherein, in the intermediate position, the distal tip of the valve pin restricts the flow rate of the molten injection fluid to be less than the maximum flow rate. The source of the endothermic fluid (260, 125f); and At least one channel (25, 33, 125) is formed in or near one or both of the actuator housing (940h, 941h, 942h) and the drive seat (940ds, 941ds), and is sealedly interconnected with the source, wherein, concurrent with the injection cycle, the heat-absorbing fluid passes through the at least one channel (25, 33, 125) in a flow that absorbs heat from one or both of the actuator housing and the drive seat.

2. The apparatus according to claim 1, wherein, The drive housings (940ds, 941ds) are mounted in thermal communication with the actuator housings (940h, 941h, 942h).

3. The apparatus according to claim 1, wherein, One or both of the actuator housing (940h, 941h, 942h) and the electric actuator (940d, 941d, 942d) maintain basic thermal communication with the heatable manifold (40).

4. The apparatus according to claim 1, wherein, The at least one channel (25, 33, 125) is disposed within the heat-conducting housing, which can be installed in thermal communication with the actuator housing (940h, 941h, 942h).

5. The apparatus according to claim 1, wherein, At least one channel (25, 33, 125) is disposed within a heat-conducting base (940mc, 940mc1, 940mc2, 941mc, 942mc), the heat-conducting base being mounted in thermal communication with the heatable manifold (40), and wherein one or more of the actuator housing (940h, 941h, 942h) and the electric actuator (940d, 941d, 942d) are mounted in thermal communication with the heat-conducting base (940mc, 940mc1, 940mc2, 941mc, 942mc).

6. The apparatus according to claim 1, further comprising: A linear stroke converter (15) interconnected with the actuators (940, 941, 942) allows the valve pins (1040, 1041, 1042) to be driven along a linear axis (X), which may be non-coaxial or coaxial with respect to the drive axis (Y) of the actuator.

7. The apparatus according to claim 6, wherein, The at least one channel (33) is disposed within a heat-conducting base (940mc, 940mc1, 940mc2, 941mc, 942mc), the heat-conducting base (940mc, 940mc1, 940mc2, 941mc, 942mc) being installed in a heat-conducting communication with the heatable manifold (40), and the linear stroke converter (15) being installed in a heat-conducting communication with the heat-conducting base (940mc, 940mc1, 940mc2, 941mc, 942mc).

8. The apparatus of claim 1, wherein the actuator further comprises: Drive components (150, 940l); and The drive mechanism is a transmission device (190, 191) that allows the driver (940dr, 941dr, 942dr) to linearly drive the drive member (150) through the rotor (250, 940r, 941r, 942r) or a linear drive mechanism (940ld) that allows the driver to directly linearly drive the drive member (940l).

9. The apparatus according to claim 1, wherein, One or the other or both of the actuator housing (940h, 941h, 942h) and the drive seat (940ds, 941ds) are at least partially made of metallic material and are mounted to the heatable manifold (40) in substantially direct metal-to-metal thermal communication.

10. The apparatus of claim 1, wherein the electrical driver (940d, 941d, 942d) includes a pulse width modulator (PWM) that converts received electrical energy into a reciprocating voltage waveform signal adapted to drive a corresponding phase coil of the driver (940dr, 941dr, 942dr).

11. The apparatus of claim 7, wherein the linear travel converter further comprises: The converter housing (120, 940lh) is mounted to be in direct or indirect thermal communication with the heatable manifold (40) and the actuator housing (940h, 941h, 942h).

12. The apparatus according to claim 1, wherein, The one or more sensors (950, 951, 952) are configured to generate one or more sensor signals to indicate one or more of the following: The pressure of the molten injection fluid (18) within the flow channel (19); The temperature of the molten injection fluid (18) within the flow channel (19) of the heatable manifold (40); The pressure of the molten injection fluid (18) within the nozzle channels (42, 44, 46); The temperature of the molten injection fluid (18) within the nozzle channels (42, 44, 46); The pressure of the molten injection fluid (18) within the mold cavity (30); The temperature of the molten injection fluid (18) within the mold cavity (30); The pressure of the molten injection fluid (18) inside the barrel of the injection molding machine (13); and The temperature of the molten injection fluid (18) inside the barrel of the injection molding machine (13); as well as The actuator controller (16) is configured to respond to at least one of the one or more sensor signals to direct at least one operation of the actuator (940, 941, 942) or its associated valve pin (1040, 1041, 1042), the at least one operation including: During the injection cycle, the device moves to a position corresponding to a predetermined profile, wherein the predetermined profile is associated with a set of injection fluid pressures, barrel screw positions, barrel pressures, or actuator drive fluid pressures corresponding to at least one of the one or more sensor signals.

13. An injection molding method, comprising: Actuator housings (940h, 941h, 942h) are provided to support electric actuators (940d, 941d, 942d), wherein supporting the electric actuator includes mounting the electric actuator inside the actuator housing, or mounting the electric actuator on or to the actuator housing via a drive base (940ds, 941ds); Heating the heatable manifold (40); Molten injection fluid (18) from the injection molding machine (13) is received at the heated manifold (40). Essentially, the molten injection fluid is maintained at a selected temperature; The molten injection fluid from the heated manifold (40) is received in a flow channel (19) formed by the heated manifold (40) and at least one nozzle (20, 22, 24); The molten injection fluid is delivered to the gates (32, 34, 36) of the mold cavity (30). The electric actuators (940d, 941d, 942d) distribute a controllable amount of electrical energy to the actuators (940dr, 941dr, 942dr) during the injection cycle. The driver responds to controllable changes in electrical energy; One or more sensor signals are generated by one or more sensors (950, 951, 952) to indicate one or more of the following: Rotational position of actuators (940, 941, 942); The linear position of the actuators (940, 941, 942); The position of the valve pins (1040, 1041, 1042) associated with the actuators (940, 941, 942); The actuators (940, 941, 942) move the valve pins (1040, 1041, 1042) to control the flow of melt injection fluid (18) into the mold cavity (30), wherein moving the valve pins (1040, 1041, 1042) includes: in response to at least one of the one or more sensor signals, the actuator controller (16) directs at least one operation of the actuators (940, 941, 942) or their associated valve pins (1040, 1041, 1042), the at least one operation including: During the injection cycle, the device moves to a position corresponding to a predetermined profile, wherein the predetermined profile is associated with a linear or rotary pin position corresponding to at least one of the one or more sensor signals and a linear actuator or valve pin position. Exit from the closed gate position upstream at a reduced speed along the selected upstream travel path; The valve pin travels downstream at a reduced speed along a selected downstream travel path, wherein the distal tip of the valve pin moves to the gate closed position; or The valve pin is moved upstream or downstream to an intermediate position between the gate closed position and the fully upstream position, wherein the valve pin is held in the intermediate position for a selected period of time during the injection cycle, and wherein, in the intermediate position, the distal tip of the valve pin restricts the flow rate of the molten injection fluid to be less than the maximum flow rate. Simultaneously, the injection cycle is performed, allowing the endothermic fluid to pass through at least one channel (25, 33, 125), said at least one channel (25, 33, 125) being formed in or near one or both of the actuator housing (940h, 941h, 942h) and the drive seat (940ds, 941ds); and Heat is absorbed from one or the other, or both, of the actuator housing and the drive seat into the endothermic fluid.

14. The method of claim 13, wherein driving the actuators (940, 941, 942) comprises: Drive the drive component (150) along the linear drive axis (Y); as well as The valve pins (1040, 1041, 1042) are driven along the non-coaxial pin shaft (X).

15. The method of claim 13, wherein driving the actuators (940, 941, 942) comprises: Drive the drive member (940l) along the linear drive axis (X); and The valve pins (1040, 1041, 1042) are driven along the coaxial pin shaft (X).

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